SERVICE MANUAL FOR KE
Contents
1. SERVICE MANUAL FOR KE 100 S Au UM orother 1 SPECIFICATIONS Me 06 1 O Ui 4 C9 t9 CONTENTS ZSBRCHEICATIONS cere ee D IEEE QUICK TROUBLE SHOOTING CHART NOTES FOR CHECK AND REPAIR eere erre CIRCUITRY CONFIGURATION So eeee eo erae ereen oense DISASSEMBLING FOR EASY CHECKING esee REMOVING THE MOTOR HEAD eere DISASSEMBLING THE MOTOR HEAD eere ASSEMBLING THE MOTOR HEAD eer REMOVING THE AC POWER CORD ee REMOVING THE SHUTTLE ASSEMBLY ee HOW TO REPLACE THE DRIVING BELT DISASSEMBLING AND ASSEMBLING THE SHUTTLE BASE MOUNTING THE SHUTTLE BASE AND THE MOTOR HEAD ADJUSTING THE TENTION OF DRIVING BELT CHECKING THE FUNCTION OF THE ROW COUNTER CHECKING THE ELECTRONIC PARTS ee r tr 9n Operation H 28 courses min 180 stitches 50Hz E uM L 20 courses min 180 stitches SOHz E M i ai e i ai e Function Operation range control 1st 200sts Operation mode control Continuous Intermittent BENE et Operation speed control High Low Preset row conter Preset row conter 0000 9999 Max 10000 rows 9999 Max 10000 rows Others Overload stopping system Yarn run out sensor Knot sensor Output 100W Power consumption 200W 100V 60Hz 117V 60Hz 220V 502. 8 3 Mounting the Yarn Sensor Connector P C B Insert the sockets into the holes on the frame then fasten them by the nuts Refer to Fig 40 Fig 40 8 4 Mounting the Magnet for Sensor Put the Magnet in the right box of the Magnet holder Make sure that the dot marked face of the Magnet should be against the Head frame Refer to Fig 41 Magnet Dot marked face e Never use Sensor magnet holder Fig 41 8 5 Mounting the Sensor Magnet Holder and the Sensor Belt to the Head Frame Sensor belt to the Head frame 1 While being the notches of the Belt inside put the Magnet holder on the Belt Refer to Fig 42 Sensor belt Magnet Adjust the belt in this groove Sensor magnet holder Put it on correctly Fig 42 2 Push the sensor belt spring to the direction of the sensor driving pulley and set the belt to the driving pulley and the idle pulley Note The sensor belt should be under the Sensor belt presser and the Row counter operation lever should engage the notch of the belt Refer to Fig 43 Sensor belt presser Row counter operation lever Sensor belt Right Fig 43 1 Sensor belt presser Row counter gt operation lever WAAR POD LSS Sensor belt Wrong Fig 43 2 cippus 8 6 Mounting the Right Left Range Sensor P C B for the Opera tion Range Knob If you replace the right left range sensor P C B fix the P C B on the
3. You have to connect these connectors firmly otherwise the Shuttle would not turn at the turning position Left Right range sensor P C B Connector Don t twist the cords Fig 64 2 Another end of each cord connected with the Control S W P C B should be inside of the Head frame and the cords should be along by the Row counter Refer to Fig 65 Cords Control SW P C B Fig 65 3 Fix the control panel with the two screws 3x8 4 Bend cord clip to clip the cord on the right side Refer to Fig 66 Control SW P C B Cord Cord clip Fig 66 92 9 REMOVING THE AC POWER CORD Note 1 Never connect the connector CN1 as CN4 and AN3 as CNS nor vice versa because they are very similar connectors to each other 2 Connect each connector with the right plug firmly Pins Connection Start Stop SW of the control panel Encorder P C B Yarn sensor connector P C B 9 1 Removing the AC Power Cord 9 1 1 Mold type Disconnect the connector P1 from the main P C B and take out the Power SW and the strain relief of AC power cord See Fig 69 Address CN1 Pull up switch Row counter SW Strain relief Safety SW for speed change Mode SW and LED of the control panel 9 1 2 Cord bush type 1 Remove the earth terminal which is on the bottom of the Head frame by removing the screw and washer
4. CN7 5V Motor driving Yarn sensor circuit 45V connector P C B 5 ees CN7 cru v uL ux RET Power supply Filter IC regulater circuit circuit CN4 CNS Main P C B assembly Row counter SW Transformer Safety SW for Speed change Fig 1 1 Connection Start Stop SW of the control panel Encorder P C B 4 2 Main P C Board The Main P C Board is composed of the Filter circuit Power supply circuit Motor driving circuit and C P U 4 bits micro computer 1 Power supply circuit The AC power which is input through the AC cord and the Power switch will be filtered by the Filter circuit to cut out the line noises and it is supplied to the motor and the transformer Then the voltage of AC power should be decreased to about AC 9V by the Transformer This is finally rectified and stabilized into DC 5V then supplied to the Main P C B and the other P C B 2 Motor driving circuit The motor is driven and controled by the SSR Solid state relay No 1 and No 2 While the shuttle is travelling to the right the SSR 1 is ON and the SSR 2 is OFF and vice versa 3 CPU This is a 4 bits CMOS micro computer and worked by 5V DC power The CPU controls both of the SSRs and the Direction indicators LED by judging the signals from the various switches and the sensors according to the program 4 3 Encorder P C B The
5. Is the voltage Replace ACO9 1 5V the Main P C B Return to start Not bad bad 30 16 2 Checking the Stator Windings of the Motor In case the motor does not run or runs in unusual speed check each resistance according to the following table and if there are any defects please replace the motor Check with a electric tester Black Bluc Cases Brown 110V Gray 120V Yellow 220V Red 240V Line C s color is different between cach voltage E pe 16 3 Checking the Yarn Sensor Function 1 Insert the troubled plug to the jack of the connector 2 Remove the yarn from the Yarn tension unit and hang the yarn sensor lever on the pin of the yarn sensor 3 Set the yarn knot sensor on the normal position 4 When you replace the sensor switch and or plug with cord 1 Turn off the power SW and please check up the function again after replacing disconnect the AC plug from the outlet Q Insert the plug of Yarn sensor 4 D Disconnect the plug of yarn Blue to the juck of connector sensor from the Motor head 3 D Disconnect the plug of yarn O P C B Hang the yarn sensor lever to sensor from the Motor head Disconnect the connector the pin of yarn sensor Drop the yarn sensor lever CN3 from Main P C B Measure the resistance be ie n resistance be Remove the yarn sensor lever tween part and part B tween part and part nu from the pin of yarn sensor and see Fi
6. 15 7 4 Removing the Gears 1 Lift the Speed change knob up to separate it from the gear and pull the knob to the direction of the arrow indicated in Fig 16 to remove the knob Speed change knob spring is also removed Speed change knob Speed change knob spring Fig 16 10 2 Pull out both speed change gear and Driving shaft with gear simultaneously The Ball bearing A is remained in the Head frame and the Ball bearing B will be in the gear box or on the Driving shaft Refer to Fig 17 Speed change gear Gear 4 Ball bearing B Gear 2 7 5 Disassembling the Gears 1 Remove the Snap ring E9 then the Gear 2 and the Gear 3 will come off the Driving shaft Refer to Fig 18 Snap ring E9 Driving Shaft Fig 18 2 Take out the Spring pin AW4 by using the stick diameter is about 3 0 3 8 m m and the hammer The Gear 5 will come off the Driving shaft Refer to Fig 19 Take off the Pin Support with something Fig 19 7 6 Removing the Motor Assembly 1 Remove the three screws which are inside of the Gear box The gear box comes off Refer to Fig 20 Remove the 3 screws Fig 20 2 Take out the Spring pin AW 2 5 by using the stick 9 2 0 m m and the hammer The Gear 1 will come off Refer to A in Fig 21 3 Take out the Spring pin for the Fan in the same way as the step 2 Refer to B in Fig 21 Hit wit
7. See Fig 70 1 Pi Earth terminal Head frame left right range sensor P C B from the control panel AC source 3 Bundle the cords and clip them with the cord crip on the Main P C B Note 1 Make sure that the cord for Encorder P C B never touch the Fan 2 by moving the operation range knob to the right and left check if the right and left operation range sensor cords move freely Never entangle each other 8 18 Mounting the Motor Head Cover Refer to the item 5 2 on page 7 Fig 70 1 2 Disconnect the connector P1 from the Main P C B and take out the Power SW 3 By using the pliers pull the cord bush out See Fig 70 2 23 10 REMOVING THE SHUTTLE ASSEMBLY 9 2 Mounting the AC Power Cord To remove the Shuttle assembly the motor head should be removed in 9 2 1 Mold type See Fig 71 advance Connect the connector P1 with the Main P C B push in the Power SW and T the strain relief 1 Remove the bolt 5x8 and washer which is on the bottom side of the ET rail at the right end Refer to Fig 73 T 2 Remove the bolt 5x25 Washer and the Right end cover for the rail Refer to Fig 73 Right end cover Remove 9 2 2 Cord bush type See Fig 72 1 1 Set the bush on the AC power cord and while holding the bush with the pliers put it on the Head frame 3 Pull the Left end cover so that the idle pulley will come out Refer to Fig 7
8. Encorder P C B sends the signal to the CPU to make the CPU recognize the revolution speed of the Motor And it is connected with the Main P C B by the connector CN2 4 4 Yarn Sensor Connector P C B There are 4 jacks Foot switch Yarn sensor switches and Jam sensor switch on the P C B and connected with the Main P C B with the connector CN3 4 5 Control Switches P C B This is composed of the Operation mode change switch S S start stop switch and the Direction indicator lamps It is connected with the Main P C B by the connectors CN1 and CN6 4 6 Left Right Range Sensor P C B These sensor P C Bs recognize the turning point of the shuttle The operation range will be fixed by these 2 P C Bs They are connected with the Main P C B through the control switches P C B by the connectors CN9L CN9R and CN7 4 7 Switches 1 Yarn sensor switch This is provided with the Yarn sensor assembly The Yarn sensor detects the troubles such as Yarn cut yarn run out and yarn knot on the yarn tension unit and if some troubles happened send the signal to the CPU to stop the motor 2 Jam sensor switch When the carriage jams over load the coupler release the carriage to keep the machine away from the damage And the lever turned into vertical position at the reverse side of the coupler comes in contact with the Jam sensor switch to stop the motor 3 Row counter switch Since the Row counter for KE 100 is a substruction counter
9. after knitting the number of row previously set the counter number comes to ZERO the Row counter switch is turned on so that the signal will be sent to the CPU to stop the motor Safety switch for speed changer The changing of operation speed is done by the gears and not by the changing of the revolution speed of the motor There is no clutch in the gear box therefore it is necessary to prevent the gear crush by stopping the motor in case the user trys to change the operation speed without stopping the motor The safety switch detects the movement of the speed change lever and if the user trys to change the operation speed without stopping the motor the safety switch works and sends the signal to the CPU to stop the motor 4 5 DISASSEMBLING FOR EASY CHECKING Before disassembling never fail to take away the AC cord plug from the plug socket 5 1 Removing the Motor Head Cover 1 Set the speed change knob on H position 2 Loosen the ten screws Round head with washer 3X8 10 pcs so that the screw head is 1 mm from the cover Refer to Fig 2 Motor head upper cover Fig 2 3 Pull the Motor head lower cover under the motor to take it away 4 Pull the cover upward to take it away Refer to Fig 3 Motor Motor head lower cover Fig 3 You can check and repair following points after removing the motor head cover A Row counter B P C board C Switches and sensors 5 2 Mounti
10. bolt 5x25 with the washer Fasten temporally Refer to Fig 84 Left end Bi iB Right end Fasten temporally Fig 84 21 13 2 Mounting The Motor Head 1 Insert the driving shaft into the hole of driving pulley with adjusting the position and fasten with three bolts Refer to Fig 85 86 14 ADJUSTING THE TENSION OF DRIVING BELT 14 1 Loosen the Safety Lock for Transportation 1 Loosen the bolt by turning it by 2 or 3 revolutions Then while pushing the end cover right side to the left not to remove it from the rail turn the bolt counterclockwise by 3 revolutions 2 Push both right end cover and bolt and fasten the bolt by the wrench 3 Turn the bolt clockwise by 2 revolutions Fig 87 14 2 Adjust the Tension of Driving Belt Refer to Fig 88 1 Place the shuttle at the center of rail Loosen the bolt on the opposite side of the motor head by the wrench until the belt touches the upper part of the shuttle 2 Then turn the bolt clockwise by 3 5 revolutions Driving belt Left and of rail Wrench 1 1 Shuttle Rear view Driving belt Shuttle 28 14 3 Incase the Adjustment of the Tension of the Belt Is Difficult In the item 14 2 during the adjustment if you feel heavy to turn the bolt before you turn it by 3 5 revolutions or if after adjusting the tension the shuttle does not move smoothly This is caused by the extended dri
11. knob with the rubber base or silicon base glue Refer to Fig 44 Right range sensor operation P C B Fig 44 8 7 Mounting the Operation Range Knob 1 Put the right side operation range knob at first then put the left side operation range knob on the sensor guide bar and snap the snap rings E6 on the grooves A and C on the shaft Refer to Fig 45 1 Note The grooves B are for the short type Motor Drivt unit _ Sensor guide bar Snap ring E6 Operation rang knob Fig 45 1 2 Pass the left end of the Sensor guide bar through the hole for it on the left side of the frame far enough then return to the right to pass the right end of the bar through the hole for it Then put the snap ring E6 on to the bar Refer to Fig 45 2 Put the snap ring E6 Fig 45 2 Note 1 The top A of the knob should be located between the belt Refer to Fig 46 2 Insert the left end of the sensor guide bar into the left side hole of the head frame then the right end into the right side hole And slide the bar to the right as much as you can 3 Snap the snap ring E6 on the right end groove of the sensor guide bar to fix it Sensor belt 18 8 8 Mounting the Row Counter Assembly 1 Set the Row counter assembly and the Display window then insert the screws into the holes on both side of the Row counter assembly 2 By moving the Sensor belt place the Row counter tripp
12. the Main P C B 9 When the Power switch is turned on both Direction 1 Troubles on the Main P C B 1 Replace the Main P C B indicator lamps light simultaneously 10 When turning on the Power switch the left direction 1 The Speed change knob is not shifted correctly 1 Reset the speed change knob pep npe pos on ang off and the motor does 2 The dropped Yarn sensor and or the leaped up yarn sensor 2 Set the Yarn sensor lever and or the Yarn norum by Wie such prevent the motor running knot sensor plate to the nomal position 3 The Jam sensor is under the sensible conditions 3 Check up the Jam sensor a 4 Troubles on the Main P C B 4 Replace the Main P C B a 11 The Direction indicator lamp for the direction that the I The yarn sensor and or the Jam sensor is under the sensible 1 Check up the Yarn sensor and the Jam shuttle is going to flashes on and off and the motor conditions sensor does not run by the S S switch 2 The speed change knob is not shifted correctly 2 Reset the Speed change knob 3 Troubles on the Main PC B 3 Replace the Main P C B I Broken of the operation mode selector switch l Replace the Control switch P C B 2 Poor connection of the connector CN6 In this case the direction 2 Connect CN6 firmly indicator lamps do not light 12 The shuttle moves only one row though the operation mode selector knob is set on
13. 1 Loosen the two screws 3X8 for the Shuttle cover and remove the 1 Put the Driving belt into the Rail and set the Shuttle base to the Rail cover The shuttle cover is facing towards you Refer to Fig 80 2 Remove the screw 3X8 and put off the shuttle spring 3 Remove the three Snap rings E8 and the six washers then the Rollers will come off Snap ring E8 Shuttle base Right end Fig 80 2 Set the Driving pulley to the Driving belt then set the pulley in the holder Refer to Fig 81 Fig 79 1 12 2 Assembling Shuttle Base See Fig 79 2 1 Put the washer the roller and another washer on the each 3 shafts for roller then put the Snap ring E8 to the shaft 2 Set the Shuttle spring by the screw 3 Set the Shuttle cover on the base and fasten it with the two screws Right end Driving pulley Snap ring E8 Pes TAIN T T I mU oveeE EC O HOP Nann Driving pulley holder Fig 79 2 Fig 81 26 3 Pull the Driving belt from another end The Driving pulley and the Holder get ino the rail Set the Idle pulley and the holder Refer to Fig 82 Left end 9 Idel pulley Holder Fig 82 4 Place the Driving pulley and the Holder which are inside of the rail at the right end and fix with the bolt 5X8 with the washer Refer to Fig 83 Right end Bolt amp washer Fig 83 5 Mount the right and left cover with the
14. 4 Sct the bush as below i dle pulley Cord bush Cord bush om Left end cover Fig 72 1 2 Connect the connector P1 with the main P C B and push in the Power switch 3 Fix the Earth terminal to the Head frame Refer to Fig 72 2 cp Earth terminal Spring washer Fig 74 Head frame Fig 72 2 24 11 HOW TO REPLACE THE DRIVING BELT 4 Loosen the bolt for left end cover and remove the idle pulley from the driving belt Refer to Fig 75 AMG loosening the bolt Idle pulley can be removed Fig 75 5 Pull the holder for the driving pulley out Then the shuttle and the driving belt will come out Refer to Fig 76 Holder for the driving pulley right end 11 1 Removing the Driving Belt 1 Take out the driving belt Refer to item 10 2 Remove the bolts 5x30 and washers for the belt clamp then pull out the Driving belt Refer to Fig 77 11 2 Mounting the Driving Belt 1 Fit the racks of the belt to the groove of the clamp then fix them with the bolts and the washers Refer to Fig 77 Note 1 The belt should not protrude beyond the clamp 2 Do not twist the belt Belt clamp Bolt amp Washer Groove Fig 77 25 12 DISASSEMBLING AND ASSEMBLING THE SHUTTLE BASE 13 MOUNTING THE SHUTTLE BASE AND THE MOTOR HEAD 12 1 Disassembling the Shuttle Base See Fig 79 1 13 1 Mounting the Shuttle Base to the Rail
15. Hz 240V 50Hz 17 kg including the stand 2 TROUBLE SHOOTING Notes 1 The Direction indicator lamp never light on and can not 1 The plug of AC power cord is not inserted into the power suply 1 Connect the plug firmly start the Motor by pushing the S S switch Socket correctly 2 Poor connection of the connector PI CN1 or CN6 3 Disconnection of Ac power cord 3 Replace the AC power cord 2 Connect P1 CNI CN6 firmly 4 Poor connection or broken of the AC power switch 4 Replace the AC power cord 5 Blown of the fuse Fl and or F2 5 Replace the fuse 6 Troubles on the Main P C B 6 Replace the Main P C B 2 Both of the direction indicator lamps are flashing and 1 Poor connection of the connector P2 or CN2 1 Connect P2 or CN2 firmly you can not start the Motor by pushign the S S switch Disconnection of the stator windings of motor 2 Replace the Motor Trouble on the Main P C B 3 Replace the Main P C B 3 The motor never run by pushing the S S switch though 1 Troubles on the S S switch of the control switch P C B 1 Replace the control switch P C B the direction indicator lamp lights correctly Troubles on the Main P C B 2 Replace the Main P C B 4 The motor Shuttle runs only in the one direction 1 Troubles on the Main P C B 1 Replace the Main P C B 5 T
16. Jam sensor base is bent so the part never touch the lever Part is bent E EET Part B is bent 3 Corrections Remove the Part and part refer to the item 16 4 1 and correct them with plires
17. e Gear 1 Put the Gear 5 on the driving shaft and fix them with the spring pin AW4 Refer to Fig 53 Hit with a hammer Support with something Fig 53 19 8 12 Mounting the Speed Change Knob Place the speed change knob on the speed change gear Gear 4 then move it to the head frame side Refer to Fig 56 2 Put the washer 12 Gear 3 and the Gear 2 on the driving shaft Refer to Fig 54 When you install the gears put some grease which is adhered to the inside wall of the Gear box to the washer and Gears Speed change knob Snap ring E9 a m mt im Head frame Driving Shaft Speed change Fig 54 gear Gear 4 3 Put some grease on the shaft for speed change gear With gearing the Fig 56 gear 4 with the gear 5 and the gear 2 install them to the shaft and the Ball bearing A simultaneously Refer to Fig 55 4 Put the Ball bearing B to the end of the driving shaft 8 13 Mounting the Gear Box and the Motor Complete 1 Set the speed change knob in the guide groove of the gear cover and put the gear cover on the head frame Refer to Fig 57 20 2 Fix the gear cover by the ten tapping screws 2X14 Note At first fasten the two screws on the A position temporally then the other screws After all screws are fastened temporally tighten them from A to the others Refer to Fig 58 Fig 58 8 14 Mo
18. e carriage to keep the machine away from the damage and the Shuttle Motor will be stopped by the Jam sensor Ball srame The Jam sensor is a kind of switch when the Part is forced to come in contact with the part B by the lever on the reverse side of the coupler the pulse to stop the motor immediately will be made and sent to the C P U Refer to Fig 96 Relative parts for the Jam sensor Fig 99 Fig 96 16 4 1 Incase the Jam sensor works even by the vibration of the motor 1 The Jam sensor is too sensitive since the clearance between the part and is to narrow The best condition is as following illustrations Refer to Fig 98 99 Part is bent inside e AA 0 t Part Jam sensor Part Q is bent Part is bent Part B Jam sensor contacter to right or left to right or left 33 3 Corrections Please make necessary corrections after removing the part and part from the Jam sensor base To remove above parts remove the screw and collar then take out the Jam sensor supporter And then remove three each of the screws and the nut so that the part and B come off Correct the bent position by using the plires Jam sensor base Jam sensor supporter Fig 100 16 4 2 In case the Jam sensor never work 1 The Jam sensor is too dull since the clearance between the part and is too wide and or the part is bent and is off its correct position 2 Wrong conditions
19. ead 7 Remove the three bolts 5x8 Fixing the Motor head to the Rail Refer to Fig 9 Support the Motor head with your hand so that it doesn t fall 8 While supporting the motor head with your hand pull it out the rail xpemmEEn LETT TT ETT T H Without washer Fig 9 Ts DISASSEMBLING THE MOTOR HEAD 3 Pull up the Control panel to remove it 4 Disconnect the Right and Left range sensor connector from the Control switch P C B Refer to Fig 12 7 1 Removing the Motor Cover Refer to 5 1 on p 7 7 2 Removing the Control Panel 1 Unfasten the Control switches P C B cords from the Cord clip and disconnect the connector No CN1 CN6 and CN7 from Main P C B Refer to Fig 10 Range sensor P C B CNI CN7 CN6 Pull off the connectors Cord clip Main P C B Fig 12 7 3 Removing the Gear Box 1 Disconnect the Motor P2 3 pins and Encorder P C B CN2 3 pins VJ Control Panel Control switches P C B connectors from the Main P C B Refer to Fig 13 Encorder P C B Fig 10 Motor 2 Remove the 2 screws screw 3x8 of the Control panel A in Fig 11 Motor cord Pull Pull up Push gt P2 Fig 11 Fig 13 2 Remove the ten screws Round head 4x16 fixing the gear box on the head frame Refer to Fig 14 Tapping screw Black Fig 14 3 Set the speed change knob on H and then remove the gear box as shown in Fig
20. ead frame Shaft for sensor idle pulley Sensor belt tension spring Fig 33 14 7 15 Removing the Sensor Driving Pulley 1 Remove the Snap ring E3 and the washer fixing the Sensor driving pulley Refer to Fig 34 Sensor idle LN Snap ring E3 Washer Fig 34 2 Remove the Snap ring E3 for the Gear 6 and remove the Gear 6 which are inside of the Head frame Refer to A in Fig 35 3 Remove the two screws 3x5 then the Bracket and the Sensor driving pulley gear will come off Refer to B in Fig 35 Sensor driving pulley Bracket for pulley Fig 35 8 ASSEMBLING THE MOTOR HEAD Note In case of putting Spring pin Sensor magnet holder Stopper There are two types of the Motor Drive Unit namely the S type only for 4 5 m m needle pitch machine and the L type all round type Since the motor head frame is a common part for both types if you need to replace it make sure that the Spring pins for the sensor Magnet holder stopper are set on the correct position The inside holes are for S type and the outside holes are for the L type Refer to Fig 36 1 L both outside holes S both inside holes Fig 36 1 To put the pin if you use the N S P operation lever 408098001 this is the part for the punch card knitting machine it can be more easily Set the N S P operation lever on the pin and hit with the hammer lightly until the pin comes out about 0 0 5 m m of reverse s
21. er to the right end Adjust the position of the row counter and fix it with screws Refer to Fig 47 Do not move the row counter tripper by force Row counter operation lever Fig 47 8 9 Mounting the Motor Assembly 8 9 1 Mounting the encorder P C B Set the Encorder P C B to the Motor as illustrated in the Fig 48 and fix it by three screws 3X6 Reverse side of motor Fig 48 Clip the cord Bend the cord to be along by the motor Encorder P C B 8 9 2 Mounting the motor fan and the Gear 1 Adjust the hole for the Spring pin 2 5 x 16 of the fan and of the shaft and push the spring pin into the hole Then hit the pin lightly by using the stick and the hammer Refer to Fig 49 Hit lightly Flat table Put into the pin so that both end of the pin come to equal length Pin 49 Fig 49 2 Mount the gear 1 to the shaft in the same way as above 1 Refer to Fig 50 Hit lightly Note 1 Take care not to breake the gear and the fan 2 If the spring pin could not be inserted into the hole never hit it strongly Fit the hole carefully and try again 8 10 Mounting the Motor and the Gear Box 1 Set the cord of the motor and the Gear box as illustrated in Fig 51 2 Mount the gear box to the motor with the three screws 4x25 Refer to Fig 52 Gcar box Motor i Fix with 3 screws Fig 51 Fig 52 8 11 Mounting th
22. g 95 see re 95 P drop the yarn sensor lever 8 LT o amp Measure the resistance be tween Red line pin No 3 and Connector CN3 Blue line pin No 4 at the metal part of the connector In case that Yarn sensor dose not work properly Red Is the resistance Is the resistance CN3 with a tester o about 0Q YES o Exchange the Yarn sensor 5 D Remove the two screws of connector P C B switch cover and Remove it EGYPT type is no switch see Fig 95 Is the resistance about 0 cover END Measure the resistance _be tween part and part see Fig 95 2 D Hang the yarn sensor lever to the pin of yarn sensor 6 D Remove the two screws of Measure the resistance be switch cover and Remove it tween Red line and Blue line EGYPT type is no switch of the connector CN3 cover see Fig 9 Measure the resistance be tween part and part B see Fig 95 Is the resistance about 0 2 Measure the resistance be Is the resistance tween part and part O 9 see Fig 7 Is the resistance Exchange the plug aa c0 with cord Yarn sensor SW and yarn sen sor connector P C B are prop Is the resistan er Exchange the Yarn sensor about 097 Exchange the Main P C B switch END 16 4 Checking up the Jam Sensor Assembly and Its Correction The function of the Jam sensor While knitting if the knitting carriage jams by the tangled yarn and so forth the coupler releases th
23. h thc Hammer 4 Unfasten the encorder code from the code clip on the motor and remove the three screws so as to remove the Encorder P C B Please do not disassemble the motor Encorder P C B Be the 3 screws Shaft for Encorder P C B Fig 22 ee T Ts 7 7 Removing the Row Counter 7 8 Removing the Operation Range Knob 1 Disconnect the Row counter connector CN4 from the Main P C B 1 Remove the snap ring E6 on the right side of Head frame Refer to A in Fig 23 Refer to A in Fig 25 Micro SW it al Hh o O O Q ee l CA y Display window Fig 25 Sensor guide bar Remove the 2 screws Fig 23 2 Move the Sensor guide bar to the left so that the right end of the sensor guide bar comes off the frame Then pull the Sensor guide bar out 2 Remove the two screws Round head 3x6 the row counter will come Refer to Fig 26 off together with the Display window Note While taking out the Row counter do not push Strongly on the both side face of it to avoid it broken down Refer to Fig 24 Motor head frame Don t push down by force 3 Remove the Snap ring E6 on the left side of the bar and take out the Operation range knob Refer to Fig 27 Epe 7 9 Removing the Sensor Belt The Sensor belt is stretched by the spring Push the Shaft of Idle pulley which is on the reverse side against the spring then the Sensor belt will become lo
24. he motor stops as if the motor is in the over load 1 Poor connection of the connector P2 1 Connect P2 firmly condition though the motor is in non load condition Disconnection of the stator windings of the motor 2 Replace the Motor li regardless of the setting position of Operation knob 5 Troubles on the Main P C B 2 Replace the Main P C B Troubles on the left range sensor P C B not turns from the left 3 Replace the Right or Left range sensor to the right or Right range sensor P C B not turn from the P C B right to the left Troubles on the encorder P C B 3 Replace the Encorder P C B Troubles on the Main P C B 4 Replace the Main P C B d 6 Though the Operation mode switch is set on the Troubles on the Main P C B 1 Replace the Main P C B i continuous mode and the number on the Row counter is pes iu a ea ene om every Tow and thel Broken of the Row counter switch 2 Replace the Row counter 7 The motor shuttle runs only in the one direction 1 Poor connection of the connectors CN7 CN8R and CN9L 1 Connect every connector firmly Troubles on the Control switch P C B 4 Replace the Control switch P C B 8 The direction indicator lamp s never light on though 1 Broken of the Lamp LED 1 Replace the Control switch P C B the motor runs in order Troubles on the Main P C B 2 Replace
25. he transportation 7 After the completion of assembling check to ensure that all connectors are properly connected and that the equipment operate normally 3 2 Two Types of Motor Drive Unit There are 2 types of motor drive unit namely L long type and S short type L type all round type S type It can not use with KH 260 for Its short rail How to distinguish between both types 1 Operation range indicator 5 4 3 2 1 O 0 1 2 3 4 65 109876543210 012345678910 I hbidbibibbibibtlibibitibtilibiblibibiblilbilulildalil I L Type 109876543210 012345678910 Pidabedstsdsbabadsdehsdcdatabstitsliteladida bods debi ted S Type 2 Difference between L and S types Parts code Head frame with shaft 414671001 415149001 Strain relief cord bush Description Difference Motor head upper cover aa MEE Operation range indicator 414757000 414872000 Length of the belt B 15 Driving belt B 25 Rail frame with name plate 415061001 415062001 Belt cover 415007000 415008000 Knitting machine setting 487435001 487436001 Length bar Disk for Table clamp 4 CIRCUITRY CONFIGURATION 4 1 KE 100 Block Diagram Important parts and their location Left range Right range sensor P C B sensor P C min Control switches P C B Operation mode SW SIS SW Yarn sensor switch gs gs w CN8R CNIL Control S W P C B AC
26. ide Refer to Fig 36 2 Hit with a hammer c Spring pin N S P about 0 0 5 m m Operation lever Fig 36 2 8 1 Mounting the Sensor Driving Pulley Gear 1 Mount the Sensor driving pulley and the Bracket to the Frame and fix t them by the two screws 3x5 Refer to B in Fig 36 3 Sensor driving pulley Fig 36 3 2 Put the Washer and the snap ring E3 on the shaft for the pulley from the front side Refer to Fig 37 Sensor idle pulley Snap ring E3 15 3 Please ensure that the Ball bearing for the driving shaft is in the right place in the Head frame then mount the Gear 6 and put the Snap ring E3 on the shaft Refer to A in Fig 36 3 Note If you have replaced the gear and or pulley put some grease on the shaft Mount the Sensor idel pulley to the shaft and put the Snap ring E3 Then insert it into the fixed place from the front side of the frame and hook the Sensor belt tension spring to the shaft from the inside Refer to Fig 38 4 Reverse side Head frame Shaft for sensor idle pulley Sensor belt tension spring Fig 38 8 2 Mounting the Row Counter Tripper 1 Mount the Row counter tripper to the shaft and put the Snap ring E3 Refer to Fig 39 2 Hook the Row counter operation spring to the pin on the frame and the Row counter operation lever Refer to Fig 39 Row counter operation spring 16
27. ng the Motor Head Cover 1 Make sure that the connectors are joined and that the Cord clips hold the cord 2 Set the Speed change knob on H position 3 Loosen the ten screws fixing the covers enough 4 Put the power switch in the Head frame securely 5 Put the Motor head upper cover on the Motor and push down it so that ali the screws are in the recess of the screw groove Then tighten the screws Refer to Fig 4 Push down Motor head upper cover 6 Tn Wrong Right Fig 4 6 Hook the Lower cover on the Head frame and push the lower cover into the Head cover Then tighten the 4 screws with supporting the under cover Refer to Fig 5 Head frame hook Under cover Support Fig 5 6 REMOVING THE MOTOR HEAD 1 Loosen the bolt on the bottom face of the right side Motor side of the rail Refer to Fig 6 Counterclockwise revolution Fig 6 2 Tighten the bolt on the right end of the rail until you feel heavy with the bar wrench after you turn it about two round Refer to Fig 7 Clockwisc e 2 revolutions Fig 7 3 Tighten the bolt which you loosen in step 1 Note By the operation 1 3 the pulley is fixed to get easy re assembling 4 Remove the bolt 5x8 and washer for the Belt cover 5 Pull out the Belt cover to the opposite direction of the Motor head 6 Take the Jam sensor Motor stop sensor Yarn sensors and plug of Foot switch out of the Motor h
28. ose remove the sensor belt from the idle pulley Refer to Fig 28 a Sensor belt spring Fig 28 7 10 Removing the Magnet for the sensor While taking the Sensor belt off the Sensor magnet holder make the Sensor magnet holder upside down The magnet will come out Refer to Fig 29 Sensor magnet holder Sensor belt Fig 29 13 7 11 Removing the Main P C B 1 Disconnect all connectors on the Main P C B 2 Remove the four screws Round head 3x8 the Main P C B will come off Refer to Fig 30 Screw Screw D cf i il Mi il it 1 3 Y R ri 3 ET 1 Screw Screw Fig 30 7 12 Removing the Yarn Sensor Connector P C B Remove the four nuts and pull the P C B out Refer to Fig 31 Pull Yarn sensor connector P C B Fig 31 7 13 Removing the Row counter tripper This work can not be done if the Main P C B has been fixed 1 Remove the Row counter operating spring Refer to A in Fig 32 2 Remove the Snap ring E3 for the Tripper then pull the Row counter tripper Refer to B in Fig 32 Row counter Operation spring B Snap ring E3 Fig 32 7 14 Removing the Sensor Idle Pulley 1 Remove the Sensor belt tension spring from the Shaft for sensor idle pulley and the Head frame base Refer to Fig 33 2 Pull off the Shaft of sensor idle pulley then remove the Snap ring E3 The Idle pulley will come off Reverse side H
29. t end Motor head 4 Set the Row counter assembly the sub cover and the row counter cover to the head frame then fasten them with the screw 3X16 Ba 5 Check up the operation of the Row counter If you move the Shuttle to the right and the left about 30 cm the number will be decreased by the e movement of the shuttle o 4 Shuttle Row counter operation lever Belt presser Belt presser Fig 92 Fig 91 Belt Latch l Belt Latch Right The belt should be in between Wrong the presser and the latch Fig 90 1 29 16 CHECKING THE ELECTRONIC PARTS 16 1 Checking the Power Supply Check each items according to below flow chart 1 D Disconnect the AC plug from the outlet and turn on the power SW Disconnect the Connectors CN1 CN7 Measure the resistance between the terminals of the AC plug C1 the resistance 1 6KQ 2 0KQ Is Fuse blowed Replace C2 FI or F2 the Main P C B 4w icio Aes cg IT ciue WH ewe h rah oh oan 5 ca ci Replace the Fuse 2 Turn off the power SW Put the AC plug into the outlet and turn on the power SW C3 Check the voltage between the cooling body of IC regulater and the terminal No 20 of CPU C2 CI AC switch Is the voltage Repl P Mai DC4 75 5 25V the Main P C B Return to start AC plug Main P C B assembly 3 Check voltage between the AC input terminals C3 Fig 93
30. the contrinuous operating position 3 Troubles on the Main P C B 3 Replace the Main P C B 13 The turning position of the Shuttle fluctuates in the I Troubles on the Main P C B 1 Replace the Main P C B i continuous operation mode e 14 The motor never stop even if the number on the Row 1 Poor connection of the connector CN4 1 Connect CN4 firmly E pz counter comes to zero 0 2 Broken of the Row counter switch 2 Replace the Row conter Troubles on the Main P C B 3 1 The position of the Sensor belt and the Row counter operation 1 Correct the positions of the Sensor belt and lever are not right the Row counter 2 Broken of the Row counter 2 Replace the Row counter E 15 The Row counter never work 3 NOTES FOR CHECK AND REPAIR 3 1 Caution in Check and Repair In order to avoid secondary damage please pay attention to the following points 1 While assembling disassembling the machine AC plug must be pulled off the socket 2 Do not disconnect the plug by pulling the cord 3 Tighten screws and nuts securely 4 Do not lose any parts Sometimes the parts screw nut washer lost and left inside of the cover cause short circuit 5 The electronical parts are weak at static electricity Be careful not to touch these electronical parts directly and hold P C boards at their edges 6 Please wrap the P C B s with alminium foil or anti static electricity bag for t
31. unting the Speed Change Knob Spring Set the Speed change knob at the rear end and hook the part B of the spring on the hole of the frame Then insert the part A into the hole of the knob Refer to Fig 59 Note If you would replace or mount again the Micro switch please set it like u not n Refer to Fig 60 Revese side of the head frame Micro switch u shape A Speed change knob spring Fig 59 Fig 60 8 15 Assembling the Control Panel 1 Put the S S switch key and the Operation mode selector knob on the control panel Refer to Fig 61 Control panel Operation mode change knob Fig 61 2 Put the control SW P C B assembly to the control panel by adjusting the two direction indicator lamps and the lever of mode selector switch to the holes on the panel and knob Refer to Fig 62 Control SW P C B assembly Fig 62 3 Fix them with the four screws 3x8 at the same time put the cord crip Refer to Fig 63 Cord clip Fig 63 b 8 16 Mounting the Control Panel 8 17 Mounting the Main P C B 1 Place the S S switch on the left side and connect the connectors for the 1 Mount the Main P C B to the Head frame with four screws Left Right range sensors with the plugs on the Control SW P C B 2 Connect each connector with the plugs on the Main P C B Refer to respectively Refer to Fig 64 Fig 68 Note
32. ving belt after long use In this case shorten the belt according to the following instructions 1 With refering to the illustratinos item 6 on page 8 remove the motor from the rail 2 Remove the driving belt from the shuttle Refer to the items 10 and 11 3 Cut off the one rack of the belt with sharp knife Refer to Fig 88 2 4 Mount the belt to the shuttle and assemble motor and the rail Then adjust the tension of the belt with refering to the instructions item 12 2 and 14 2 Cut off along by the linc Ca a a ae Fig 88 2 15 CHECKING THE FUNCTION OF THE ROW COUNTER Make sure that the main power switch is turned off 15 1 Checking the Function of the Row Counter 1 Remove the motor head cover 2 Remove the row counter 3 Push the Operation stud to the direction of arrow indicated in the Fig 89 If the number is decreased by the action of stud on each time the function of row counter is in order Sensor belt Details fil fl m ff raped allt Operation stud Sensor belt Fig 89 15 2 Checking the Operation of the Row Counting Mechanism Right position Left position 1 Check up the location of the Feeding latch Refer to Fig 90 Fig 90 2 2 If itis in the wrong location Remove the Control panel and correct it by using the screw driver from under between the head frame and the rail 3 Move the shuttle so as to place the Row counter operation lever on the righ
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