Service Manual for G-Carriage
Contents
1. covers A and B plane the cover the direction change normally knob or replace the upper G carriage cover assembly caught by The direction change assembly R and L function heavily the rest l The needle guide cam and the direction change plate slide ing needle heavily with each other due to the warp of the plate it comes i lis Adjust or replace the stitch guide cam plate and the direc off tion change plate e Adjust Direction achan Vertical movement of yarn feeder the direc change pawl change plate change plate is heavy when feed tion change Bend to adjust the yarn feeder plate by bend change plate if its bent is not right ing the direction change plate so that no clearance is Chamfer the parts shown in the right provided between them or replace the direction change figure Apply grease to the heavy Chamfer plate R and L take care not to let the direction change part adjust or replace if neces pawl function heavily sary Replace if the shaft is bent Wipe grease off the direction change pawl the surface A where the resting needle is caught The direction change is not secured due to the insufficient degree of the direction change Bend the plate of the connecting plate assembly inward so that the clearance between the hole of the upper plate A assembly and the yarn feeder change cam becomes small when the direction changes The direction change pawl does2. of the machine Replace the KH needle if the latch is out of order and the latch needle is bent Check to be sure that the KH needle is located in the middle of the teeth of the gate pegs And check the longitudinal vertical and lateral adjustments of gate pegs Bend to adjust or replace the gate pegs if necessary If the needle presser bar assembly is damaged replace it with new one With regard to the model KG 88 check to be sure that the needle position indicator of the model KH 881 is not warped and the needle does not float Replace the warped needle posi tion indicator The tilting of the G needle is improper The abnormal sound might be generated The G needle is caught Upper plate assembly Parallel G needle rotation lever assembly 3 Tilt more 3 Dropping stitches by the gate pegs if the G If the stitch drops knit with the needle tilts too much new G needle If it still drops and the stitch drops check the following points 2 8 mm if it does too little As 1 The G needle is out of order 5 5 mm or more Check to be sure that the latch tW m normally operates The latch is out of order because oil is short the latch is bent and or the spring is damaged Supply oil repair or replace if neces IL sary Detail of hook The right figure shows the 4545 dimension necessary for the G E needle Measure it to check whether it is satisfied or not Check to be sure that the needle is not bent
3. operation lever 39 Pattern selector cam _ Collar 2 pes 40 Yarn feeder change cam NS EGNCESELI IT LANE NEGO ATE Washer for yarn feeder Yam feeder change cam 2 pcs xchange lever lt Screw for yarn feeder Change lever n 39 Pattern selector cam change cam 2 pes for knitting needle Reader spring Change lever spring Selection lever 40 Screw Mounting the knitting needle operation lever 38 1 Fix with the washer and screw for the G needle operation 37 1 Put the shaft of the knitting needle operation lever into the arm G carriage plate and attach the link to the knitting needle e Mounting the pattern selector cam operation arm 39 Put the change lever for knitting needle into the square hole 37 2 Fix the knitting needle operation lever with the washer and of the pattern selector cam and place the pins of the knitting screw needle operation lever assembly and the operation lever for G Assemble so that the pin of the knitting needle operation lever may needle into the grooves and put the two collars onto the fixing locate in the outside groove of the carriage feeding cam holes Mounting the operation lever for G needle e Mounting the yarn feeder change cam 38 Attach the shaft of the operation lever for G needle into the 40 Put the yarn feeder change lever to the yarn feeder change hole of the G carriage plate and the link to the G needle cam and fix it with two washers and screws operation arm with the pin
4. 68 Attach the right and left rubber wheels with the screws and Mounting the G needle washers 67 Put the G needle into the G socket for G needle and attach Keep the protruded part inward A Assembling the G carriage eM C N Screw for DC motor braket How to replace the DC motor only 1 Disassembling the G carriage by referring to the page 6 item 1 to page 7 item 14 Turn over the carriage and remove the two screws for the DC motor bracket A Lift the G carriage foot and remove the DC motor with the DC motor bracket B Remove the two screws for the DC motor Replace the DC motor with new one Attach the two screws for the DC motor to the DC motor bracket B Screw for DC motor DC motor DC motor braket z Lift the G carriage foot and put the DC motor with the DC motor bracket while the gear in the DC motor bites the level gear Fix the DC motor bracket with the two screws for the DC motor bracket Connect the connector of the DC motor with the control board Assembling the G carriage by referring page 24 item 58 to page 26 item 68 6 HOW TO ADJUST THE G CARRIAGE Set the stitch dial to 5 Rotate the bevel gear clockwise and move the yarn feeder Adjust the stitch dial lever by moving it longitudinally holder near the control board Dimension between the rear end of the G carriage rear groove 6 Push the yarn feeder holder forward and keep it as it is by to
5. The latch should operate as smoothly as 1 3 mm Gate pegs 7 I 4 Latch needle shown in the right figure the upper plate assembly and the G needle tilting lever assembly are paral lel and the tilting degree of the G needle becomes zero Turn to adjust the G needle tilting lever in the proper direction so that the tilting degree of the G needle may be come zero Replace if the socket for G needle does not tilt in the hole of the arm for socket smoothly Arm for socket Socket for G needle 4 The needle guide is bad Replace the needle guide arm if the angle B of the needle guide is not right the needle guide is broken and there is clearance between the surface A of the 4 The wrong needle selection is performed Check to be sure that the wrong needle selection cannot be found with the K carriage If the wrong needle selection is found adjust by referring to the service manual of the machine 1 The stitch knitted by KH needle purl becomes the stitch by needle guide and the G needle when placed the G needle to the right side Surface A The moving degree of the yarn feeder is improper The abnormal sound might be generated Adjust the right movement of the yam feeder when the G carriape moves to the left as shown in the following figure Bend and adjust the pin B of the yarn feeder change plate so G needle Plain When the hole where the reader for needle selection of the feed base assembly i
6. cam f G needle operation Reader for needle selection rubber washer Change lever for knitting needle 35 Locate the pitch adjuster in the rear Keep the carriage feeding lever straight 36 Keep the lower part of the periphery of the carriage feeding cam in the rear and put it toward the reader for needle selec tion Then fit to the carriage feeding cam while lifting up the hooks of the change lever for knitting needle and the reader for needle selection Assemble the carriage feeding cam the reader for needle selection and the change lever for knitting needle securely When assembling the carriage feeding cam check to be sure that the pins of the following parts are properly set to the grooves of the cam the stitch dial cam carriage feeding cam the pitch adjus ter cam and the pattern selector cam are arranged in this order from the inside Put the hooks of the change lever for knitting needle and the reader for needle selection onto the high of the carriage feeding cam and check to be sure that it can be rotated clockwise by hand G carriage feeding cam Assembling the G carriage Knitting needle operation lever an 1 Knitting needle 40 Yarn feeder 38 Operation lever operation lever change cam for G needle 37 2 Washer for knitting needle operation lever Screw for knitting i needle operation lever 388 Operation lever for G needle 38 1 Washer for G needle operation lever Screw for G needle
7. distance between the sensor and the magnet is too far Turn the bevel gear 750 clockwise by hand and adjust the control board by checking the following three points when the sensor and the magnet come nearest with each other page 28 1 Longitudinal position See the adjustment on the page 28 Vertical position Make the hole of the control board bigger and adjust Lateral position Change the bent angle of the upper plate as sembly where the con trol board is mounted 2 The switch of the row counter assembly does not change over smoothly The row counter does not stop at 000 Check to be sure that the row counter is set to 000 Set the tester to the ohm range x 1 and connect the tester bars with the both ends of A 4 The tester should indi cate zero ohm at this time Replace the row counter assembly if not indicating zero ohm 3 The switch board is out of order 1 Ifthe stop key does not function refer to the section 2 on the page 32 the checking method of the stop switch Upper plate assembly Control board 08 2 If the G carriage does not stop at OOO set the row counter to 000 set the tester to the ohm range x 1 and connect the tester bars with the both ends of A If the tester indicates zero ohm the control board is out of order If not indicating zero ohm the switch board is out of order The sensor for yam breakage does not work If the yarn is cut before the sensor f
8. for socket G needle operation arm base G needle swing arm assembly e Removing the yarn feeder unit 60 Remove the two screw for the G needle operation arm 5 Yarn feeder holder bracket R 61 Remove the five screws for the yarn feeder holder 5 Yarn feeder 62 Release the fitting with the pitch adjuster and remove the yarn Oring feeder unit Latch presser plate assembly When it is necessary to disassemble the yarn feeder unit Yarn feeder holder assembly See the page 17 for assembly 63 Remove the pitch adjuster the G needle swing arm assembly Remove the two snap ring E for yam feeder unit and pull out the G needle operation arm base and the socket for G needle the stud so that the following parts come off e Removing the arm for socket Washer for yarn feeder change cam 64 Remove the screw for the plate spring and remove the plate 2 Latch presser plate change cam spring 3 Yarn feeder up down change cam 65 Remove the snap ring E of the stud 4 Yarn feeder holder bracket L 66 Pull out the stud 67 Remove the arm for socket Disassembling the G carriage dial Screw A for stitch cam guide plate 2 pcs Screw B for stitch cam guide plate 2 pcs Needle guide plate Screw for needle guide plate 2 pcs Stitch cam guide plate Connecting plate Direction change plate R Direction change plate L Spring for connecting lat oS 3 Screw for latch stopper brush 2 pcs Arm for
9. needle operation cam 31 Pull out the yarn feeder change plate by turning its shaft part Disassembling the G carriage Reader spring Change lever spring 0 8 Screw for yarn feeder 3 n Air change cam 2 pcs 2 37 1 Yarn feeder change cam Ef E KK C Be Collar 2 pcs ae EN i 7 Pattern selector cam d Q N Ce ja i i Screw for G needle operation lever Washer for G needle operation lever Operation lever for G needle Screw for knitting needle operation lever Washer for knitting needle operation lever Knitting Needle operation lever Yarn feeder cange cam spring 35 The reader spring comes off Removing the operation lever for G needle assembly 36 The change lever spring comes off 39 Remove the screw and washer for the G needle operation Removing the yarn feeder change cam and the pattern selector cam lever assembly 37 Remove the two screws and washers for the yarn feeder 40 The operation lever for G needle assembly comes off change cam e Removing the knitting needle operation lever assembly 37 1 Remove the yarn feeder change cam and remove the two 41 Remove the screw and washer for the knitting needle opera collars located under it tion lever assembly 38 Remove the pattern selector cam 42 Remove the knitting needle operation lever assembly Disassembling the G carriage Preser plat for spri
10. page 18 on the manual 4 DISASSEMBLING THE G CARRIAGE mark _ 2 PA Knit leader tripper Row counter tripper Set screw to fix G carriage foot 2 pes Set screw for carriage cover 3 pcs Snap ring E 3 Carriage cover Pattern selection knob Aut return knob Direction change knob G needle Rubber wheel 2 pcs Spring washer 2 pcs Needle guide arm Av Gr mark 6000000 e Removing the carriage cover 1 Pull out the leader tripper y mark and the row counter 6 Remove the carriage cover tripper 1 mark 7 The pattern selector knob comes off 2 Remowe the right and left set screws to fix the G carriage foot 8 The aut return knob comes off When only the G carriage cover is removed and the DC motor is 9 The direction change knob comes off replaced they can be detached just by loosening the screws e Removing the G needle some 3 mm 10 Pull out the G needle 3 Open the lower carriage cover and the needle guide arm 42 to e Removing the rubber wheel the left and remove one set screw and the right and left screws 11 Remove the right and left screw to fix the rubber wheels 4 Remove the connector of the motor control board from the and detach the rubber wheels and the spring washers switch board Removing the needle guide arm Do not pull the lead wire by force 123 Detuhdi estre gu tpi eie 5 Remove the snap ring E to detach the row counter connect 12 Det
11. presser plate assembly Yarn feeder holder assembly Yarn feeder holder Yarn feeder holder bracket R Yarn feeder holder bracket L Yarn feeder up down change cam Latch presser change cam Washer for yarn feeder _ change cam 5 Stud 2 pes Snap ring E 2 2 pes cut position of the yarn feeder assembly upper part Fit the hook of the latch presser change cam to the cut posi tion of latch presser plate assembly lower part and put the washer for the yarn feeder change cam Put the studs through the mounting holes of the yarn feeder holder bracket R and L as well as each cam and fix it with the snap ring E Assembling the G carriage Names of Parts Screw for yarn feeder holder bracket 5 pcs Screw for G needle operation arm base Stitch adjuster plate Yarn feeder change lever Snap ring E 4 Snap ring E 3 Mounting the yarn feeder holder unit e Mounting the stitch adjuster plate assembly 18 Slide the pitch adjuster forward and put the yam feeder 22 Put the pin of the stitch adjuster plate assembly into the pin holder bracket R of the yarn feeder unit into the square hole of the G carriage plate while putting it into the groove of the of the G carriage plate stitch adjuster cam 19 Put the boss of the pitch adjuster into the hole of the yarn e Mounting the yam feeder change lever feeder holder bracket R and put the boss of the yarn feeder 23 Fix the yarn feeder change lever into the pin of the G carria
12. retainer for reader with the spring hooked to the e Mounting the carriage feeding lever G carriage plate mount so that the one arm may be located 30 Widen the upper and lower direction change lever spring to between the stitch adjuster plates attach the carriage feeding lever Mounting the direction change lever 30 1 Put the roller to the pin of the carriage feeding lever 27 Put the boss longer part of the direction change lever into Assembling the G carriage Carriage feeding assembly G needle operation arm assembly Change lever for G carriage feeding cam knitting needle Reader for needle selection Mounting the G needle operation arm assembly 31 32 Put and fit the cut part of the G needle operation arm assem bly into the G carriage plate Put the G needle operaion shaft from the front side through holes of the G needle operation arm assembly the G needle operation base the yarn feeder holder bracket R the arm for needle operation and the G carriage plate and fix the shaft with the snap ring E 2 5 Fit the G needle swing cam spring to the shaft See No 46 on page 10 Mounting the reader for needle selection 33 Put the rubber washer to the shaft of the reader for needle selection and place the reader for needle selection on the carriage plate 34 Put the change lever for knitting needle under the carriage feeding lever and onto the G carriage Mounting the carriage feeding
13. the G needle tilting cam into the G needle operation cam and the step feeder 52 Put the G needle tilting cam by matching the mark The Be sure to put the pin into the inside groove of the G needle opera feed change cam the G needle tilting cam and the yarn tion cam which permits tilting feeder change cam are arranged in this order from the inside 48 Fix with the washer and the snap ring E Set to the proper position Mounting the bevel gear Mounting the change plate L for aut return and the change plate R 49 Put in the bevel gear and fix it with the washer for aut return Mounting the row counter connecting plate and the gear mount 53 Mount the change plate R black and L white for aut return 50 Put the row counter connecting plate to the gear mount and put the springs to the change plates assembly and attach to the shaft of the bevel gear while 23 Assembling the G carriage 66 Upper plate assembly 64 1Snap ring E 4 4 pcs 6 Screw for gear mount 3 pcs 66 Direction change lever B assembly Snap ring E 3 65 Direction change lever A assembly Snap ring E 3 8 Binder 2 pcs 69 Pattern selection knob 60 aut return knob 60 Direction change knob I T s Binder Mounting the upper plate assembly e Mounting the connector of the DC motor when the binder is cut 54 Mount the upper plate assembly onto the shafts 58 When detaching the control board fix the lead
14. Service Manual for G Carriage brother MODEL KG 88 89 ND BR w a OOS o Ro Pare eis OM ERES S Es Cre eT vr 0 KZ E ONCE l EASA Ku SDECITICSTIOTIS 20 seus oes General comparison between KG 88 amp 89 sees nm 2 Table fOr TONDE SHOOTNE ou rumor mn ais Ee M c Disassembling the G carriage 60 ba zu cans aes 1707 iG AnsembEne the OCA easier Ce ava Ede Rc no ete AEDE 14 116 7 0 5 7081 4116 07 0933113396 onc bu eere trm rum mon tomi 27 Disassembling and assembling the adaptor Ls 28 Disassembling and assembling the sensor for yarn breakage 29 EGBA EOE UR Leod aet iR elle ER vx vt MU 1 FEATURES 2 SPECIFICATIONS Gcarriage 1 Knitting system of G carriage 2 Knitting speed About 0 6 0 8 sec Jstitch It is possible to knit plain stitch rib stitch garter stitch and multi ___ofGearriage variable in a little range by the volume of the adaptor garter stitch pattern Plain stitch 3 Patterning Multi garter pattern Combination pattern of Automatic casting off is possible function lain and purl asting off Yarn breakage is sensed by the sensor to stop the carriage auto Same as the knitting machine matically 4 Needle selection The needle is not selected preliminarily and the knitting is done while select
15. ach the eee gui assembly ing plate See Fig on page 25 control board When the control board and the DC motor are not removed do not cut the connected binder of the upper plate assembly 13 Cut the connected binder of the upper plate assembly with attention to the lead wire 14 Remove the connector of the DC motor which connects with the control board When only DC motor is remove see page 27 Note Do not pull the lead wire See Adjusting the control board on page 28 for removing the control board Removing the direction change lever A assembly and the direction change lever B assembly 15 Remove the two snap rings E 3 for the direction change levers A and B assembly 16 Remove the direction change lever A assembly 17 Remove the direction change lever B assembly Removing the upper plate assembly 18 Remove the four snap rings E 4 which fixes the upper plate assembly Removing the motor lead wire and the lead wire for the motor Binder 2 pcs Connector Snap ring E 3 2 pcs Direction change lever A assembly Direction change lever B assembly ae n Snap ring E 4 4 pcs Screw to fix gear mount 3 pcs Upper plate assembly Spring for change plate Change plate R for aut return Spring for change plate Change plate L for aut return G needle tilting cam G needle tilt lever assembly Gear mount assembly Row counter connecting plate Bevel gear amp bevel gear wash
16. e operation cam Locate the yarn feeder change cam in the rear Put the pin into the outside groove of the G needle operation cam which permits the rotation e Mounting the yarn feeder holding cam spring 45 Put the longer pin of the yarn feeder change plate assembly into the center square hole of the yarn feeder change cam spring and fix them with the screw by pressing against the pattern selector cam and yarn feeder change cam See Fig on page 21 Assembling the G carriage Washer and snap ring 3 j BF E 4 for latch presser zr iy eal 7 7 E 1 lever swa gt A He Latch presser lever assembly Washer for latch presser Snap ring E 4 Bevel gear Row counter connect ing plate Gear mount G needle tilting lever assembly G needle tilting cam Change plate R for aut return Change plate L for aut return Spring for change plate 2 pes Mounting the latch presser lever assembly 46 Attach the washer and snap ring E under the groove of the putting the pin into the feed change link R step feeder knitting needle operation lever assembly shaft Mounting the G needle tilting lever assembly 47 Put the pin of the latch presser lever assembly into the yarn 51 Mount the G needle tilting lever assembly while putting the feeder up down change cam and the latch presser change G needle swing arm and the step feeder together cam through the knitting needle operation lever shaft and Mounting
17. er 19 Remove the three screws which fix the gear mount 20 Pull up the upper plate assembly slowly for removal Removing the change plates R and L for aut return 21 Remove the spring for change plate and the change plate R for aut return 22 Remove the spring for change plate and the change plate L for aut return Removing the G needle tilting cam 23 Pull out the G needle tilting cam Removing the G needle tilt lever assembly 24 Remove the G needle tilt lever assembly Removing the gear mount assembly and the row counter connecting plate 25 The gear mount assembly comes off 26 And the row counter connecting plate comes off at the same time Removing the bevel gear 27 Removing the bevel gear and the bevel gear washer Disassembling the G carriage Screw for step feeder 2 pes Step feeder Removing the latch presser lever 28 Remove the snap ring E and the washer for the latch 32 Pull out the G needle operation cam presser lever Removing the step feeder 29 Remove the latch presser lever assembly and the washer 33 Remove the right and left two screws which fix the step e Removing the yarn feeder change cam spring feeder 30 Remove the screw for the yarn feeder change cam spring and 34 Pull up and remove the step feeder slowly detach the yarn feeder change cam spring Pay attention to the lead wire for the DC motor e Removing the yarn feeder change plate assembly and the G
18. ews so that the A of the socket for G needle and put the pin B of the arm for condensor side may be located on the right side socket into the cam hole B of the G needle swing arm at the e Mounting the socket for G needle same time 12 Put the socket for G needle into the hole of the arm for Put the boss C of the G needle swing arm into the hole C of socket the G needle operation arm base and fit them to the carriage e Mounting the G needle swing arm the G needle operation base plate and the pitch adjuster Open the foot assembly of the G carriage and fit the hole D 13 Put the pin A of the G needle swing arm into the open part of the pitch adjuster to the stud At this time put the boss E of the pitch adjuster into the hole E of the G needle opera tion arm base Fix the G needle operation arm base temporarily with two screws Assembling the G carriage assembling the yarn feeder unit Yarn feeder holder Washer for yarn feeder change cam D Yarn feeder holder assembly Yarn feeder holder bracket L Latch presser plate assembly Mounting the yarn feeder holder unit 1 Put the yarn feeder holder assembly into the latch presser plate assembly and mount the yarn feeder holder assembly 2 Put the O ring of P 9 to the arms of the yarn feeder holder assembly at their left side and fit the yarn feeder holder bracket R and L to them 3 Fit the hook of the yarn feeder up down change cam to the U Latch
19. fit the rail and stitch cam guide plate releasing hand from it KG 89 33m m 7 Place the control board near the yarn feeder holder so that KG 88 34 1 m m the board may not get contact with the holder and fix it with 4 Fix with the stitch dial screw two screws for control board Adjusting the motor control board Note The yarn feeder holder should not get contact with the control board g 7 DISASSEMBLING AND ASSEMBLING THE ADAPTOR D Screw for adaptor box 3 pes Adaptor box lower 3 Power supply board adaptor Screw for volume 2 pes 5 Speed control Adaptor box cover upper Disassembling the adaptor e Assembling the adaptor 1 Loosen the three screws for adaptor box and remove the 5 Put the speed control knob to the speed control board lower adaptor box 4 Fix the speed control board onto the upper adaptor cover with 2 Detach the connector of the speed control board from the the two screws power board 3 Put in the adaptor and the power board together and attach 3 Remove the bush of the cord and detach the power board the bush of the cord and the adaptor upward Attach the connector of the speed control board to the power 4 Loosen the two screws to remove the speed control board board 5 Remove the speed control knob 1 Attach the lower adaptor cover and fix it with the three SCIews gU 6 DISASSEIVIBLING AND ASSEMBLING THE SENSOR FOR YARN BREAKAGE Names
20. ge holder bracket R into the hole of the G needle swing arm plate with the snap ring and into the pin of the connecting 20 Fix the yarn feeder holder bracket R and L with five screws plate with the snap ring 21 Fix the G needle operation arm base with two screw 18 Assembling the G carriage Direction change lever Link for pitch adjuster spring Washer tapping screw Fi Pitch adjuster lever P Retainer for reader Presser plate for spring lt p Spring for retainer holder Direction change lever Spring hanger plate Spring hanger plate upper lower N AS tes hanger plate Direction change lever spring Bw Presser plate for spring Spring hanger plate il holder 30 Carriage feeding lever Roller for carriage feeding lever e Mounting the link for pitch adjuster and the pitch adjuster lever the cut part of the yarn feeder holder assembly and put it into 24 Set the hole of the link for pitch adjuster to the boss of the the pin of the G carriage plate pitch adjuster and fix them with the washer and tapping screw 28 Attach the spring hanger plate lower and upper to the direc 25 Put the pitch adjuster lever into the pin of the G carriage tion change lever and hook the direction change lever spring plate while putting it into the hole of the link for pitch adjuster Attach the presser plate for spring holder to the direction change e Mounting the retainer for reader lever 26 Attach the
21. ge 38 See Trouble shooting on page 38 See Trouble shooting on page See Trouble shooting on page 37 1 Pin Plug Carriage Power Plug Note 1 Put the pin plug O of the carriage first for use and then the power plug Be sure to pull off the power plug 2 when not in use f you put and pull the pin plug of the carriage with the power plug connected the fuse in the adapter might sometimes melt and break Note 2 When you carry the carriage within the box 1 Set the direction change knob to the right and turn over the G carriage 2 Check to be sure that the reader for needle selection comes down If not repeat starting and stopping until it comes down Note 3 When you use improper yarn which cannot be knitted with the G carriage the carriage will be damaged which leads to drop stitch See Knitting yarn on page of the manual Note 4 After you hold up the front part of the carriage and move just for no load running be sure to put it down slowly at the position A where no fabric is hunged otherwise the stitch cam guide plate might be damaged Note 5 When you put down the carriage onto the needle bed after holding up and moving its front part be sure to move the carriage laterally to put it down if there is clearance provided between the G carriage cover and the foot If you force the carriage down the feed pawl of the step feeder might be damaged See the
22. ge x 1 and connect the plus side of the tester bar with the white part and the minus side with the black part for check ing the value of resistance When zero ohm Detach the DC cord from the board set the tester to the ohm range x 1 and connect the plus side of the ed E 3 with the DC plug disconnected with the carriage When the fuse is broken again replace the power board When the fuse is not broken check the output voltage of the pin plug again If no abnormality is found the adapter functions normally When the fuse is not broken Connect with the AC receptacle Set the tester to the DCV range and connect the plus side of the tester bar with the white part and the minus side with the black part to check that the output voltage is within the range from 11V to 13V When DC voltage Replace the DC cord and the curl cord When not DC voltage Set the tester to the ACV range and check the voltage of AC 1 and AC 2 AC 14V 15V AC2 9V 10V When the voltage of AC 1 amp AC 2 is normal replace the power board When the voltage of AC 1 amp AC 2 is not normal replace the adaptor b When the pin plug is loaded with the output voltage Check the DC motor assembly The tester indicates zero ohm when the stop switch is Detach the connector of the motor from the motor control pressed When not indicating zero ohm replace the board Set the tester to the ohm range x and perform swi
23. hrough the oval hole guide plate ofthe G carriage e Check to be sure that the stitch dial rotates and each part securely 8 Mount the direction change plate R and L which pull against fit to the stitch cam guide plate 9 4 Fix the stitch cam guide plate with two screws A 9 5 Fix the stitch cam guide plate with two screws B 9 6 Fit the stitch dial lever with stitch dial washer and screws Adjust the yarn take up dimension see the page 27 Mounting the stitch cam guide plate 10 Fix the stitch cam guide plate with screws so that the chamfers of the holes of the stitch cam guide plate may be kept upward each other with the spring for connecting plate so that the cut parts of the direction change plate may fit to the both ends of the connecting plate e Mounting the stitch cam guide plate set the stitch dial to 7 9 1 Put the boss of the stitch cam guide plate into the groove of the stitch dial knob 9 2Put and fit the arm for needle operation into the center groove of the stitch cam assembly e Assembling the G carriage i DC motor Screw for DC motor 2 pes 2 Socket for G needle 3 G needle swing arm 4 G needle operation _ CH _ arm base Link for pitch S Pitch adjuster edle j 6 Screw for G needle operation base 2 pcs G needle swing B arm spring G needle swing arm E Socket for G need e Mounting the DC motor 11 Mount and fix the DC motor with two scr
24. ing the needle at the same row Automatic knitting is possible If the number of rows is set the carriage stops after knitting the s Safety device SELE GEAR ESE set number against trouble Overload automatic stop The design is selected by utilizing punch cards Single motif pattern is possible by using the G point cam 1 consumption Easy operation is possible Eu EIE 9 Combination of 1 When the model KG 88 is used with the model KH 881 860 the usage is permitted within the range knitting machine from 95 on the left to 95 on the right otherwise patterning is sometimes impossible 2 When the model 88 is used with the model KH 910 the machine should be modified with the new pattern case whole unit It is possible to knit all 200 stitches General Comparison Between KG 88 amp 89 Two types of the G carriage are available KG 88 and 89 Choose the type suitable to the knitting machine to use according to the specification Name of Parts 1 Step feeder B45 G Carriage Assembly 2 Carriage Foot B79 3 Direction change plate R L B91 4 Magnet Holder C134 Adaptor A18 35 1 Racks D21 23 2 Tripper D14 18 Accessory e Feed position KG 88 plate and feed plate are shorter as compared with KG 89 To use auxiliary rack mentioned hereafter e Groove to fit to rear rail is wider as compared with KG 89 To use auxiliary rack e G carriage returns whe
25. ings into the switch keys from the rear side 62 Let the lead wire of the control board between the carriage of the G carriage cover place them properly put the switch cover and the shaft to mount the G carriage cover and put the board over them and fix it with three screws G carriage cover over it And fix with the two screws for G 2 Fix the row counter window and the row counter assembly carriage foot with three screw 63 Fix the row counter connecting plate to the center pin of the The switch key functions to start green and to stop red row counter with the snap ring E Disassembly 1 Loosen the three screws shown in Fig to 64 Attach the connector of the control board to the switch detach the row counter and the row counter board window Take care not to let the lead wire get contact with the row counter 2 Loosen the three screws shown in Fig 1 to connecting plate and the bevel gear detach the switch plate the switch spring and the switch key EL Assembling the G carriage Names of Parts Screw for G carriage 3 pes Needle guide arm G needle Rubber wheel Washer for rubber wheel Screw for rubber wheel 2 pcs respectively 65 Fix the G carriage cover with three screws 65 1 65 2 amp 65 3 the lever of the G needle operation arm assembly to the G Mounting the needle guide arm needle 66 Put the needle guide arm assembly to the boss of the pitch e Mounting the rubber wheel adjuster
26. ller and spring into the groove of the stitch dial 2 Mount the arm for socket onto the socket base insert the stud lever and set the cover from the back and fix the arm with the snap ring 2 Mounting the G carriage foot assembly ep 3 Attach the spring for G needle socket with screws 5 Fix the G carriage foot assembly temporarily with screws at Mounting the stitch dial two positions so that it may not come inside the G carriage 4 1 Mount the stitch dial lever onto the G carriage plate and fix plate it with screw temporarily Mounting the arm for needle operation t 6 Put the arm for needle operation through the hole of the G carriage plate S Assembling the G carriage Names of Parts T Connecting plate B Direction change plate R Direction change plate L Spring for connecting k E i D m _ plate f go i TS ia E a Stitch cam guide plate jJ ANS e Ei Ha 4Screw A for stitch l a y cam guide plate _ Qpok 2 5 Screw B for stitch cam guide plate Hi 2 pes 8 5 Stitch dial washer Stitch dial screw 9 Guide plate Screw for stitch cam guide plate 2 pcs 9 3 Widen the space between the direction change plate R and L e Mounting the connecting plate and the direction change plate R and L a little in both lateral directions and fit to the stitch cam 7 Put the pin of the connecting plate t
27. m is out of order 4 Replace fuse or DC cord assembly 5 Row counter is set to 000 5 Reset counter i 6 Each knob stops inbetween 6 Set knobs properly 7 Pin comes off cam groove 7 Reassemble G carriage stops in the 8 G needle does not move due to knot and float 8 Set G needle for operation and press start key again middle of movement gc 9 Yarn is entangled with yarn tension unit 9 Remove entanglement 10 G point cam various types floats and is not located 10 Set the cam to proper position Adjust the curve of properly ES l rack in case of KG 88 11 Needle of knitting machine comes forward position B 11 Locate the needle to position B and 8 contact with G Motor runs but carriage 7 n 12 Replace G carriage plate assembly 7 stops _ 13 Replace gear mount assembly _ 14 Replace step feeder TE 15 Bend to adjust mi moves without automatic return 2 Feed change pawl does not function smoothly lace feed change plate assembly See Assembling the G carriage on page 14 Motor stops at return 3 Direction knob does not work smoothly lace See Trouble shooting Poston 4 Direction change plate assembly R does not i e directii on page 35 work smoothly i 5 Yarn feeder change plate does not smoothly move up and down 6 Allowance for direction change is insufficient 7 Row c
28. n moved 32 pitch in the same manner as KG 89 Because of needle change mechanism of knitting machine No need to attach DC cord is so long that sopo can be located on foor no place provided for attac machine ing the adaptor on knitting Rack R M amp L attached parts for feeding G carriage Knit Leader tripper A Row counter tripper A amp knit leader tripper for KH 860 G point cam Li G point cam R1 G point cam for 2 needles G point cam for 3 needles Color green Attached Because sensor for varn breakage cannot be attached to yarn sensor head of old model machine For KG 89 For KG 89 G carriage returns when moved 26 pitch after G carriage passes end needle of knitting machine No need to attach Not provided No need to attach because it has a built in rack at rear rail of knitting machine Knit Leader tripper A Row counter tripper A G point cam L1 G point cam R1 G point cam for 2 needles G point cam for 3 needles Color sand beige Attached on knitting machine TABLE FOR TROUBLE SHOOTING c m Probable Cause 7 G carriage does not move 1 Power cord is not connected with the receptacle 1 Connect power cord SM See Trouble shooting from the beginning 2 Pin plug is not connected 2 Connect plug 31 in operation 3 Sean bar of sensor for yarn breakage comes 3 Put up the bar over knitting yarn own 4 Electrical syste
29. needle operation Stitch dial lever Roller and spring Stitch dial Stitch dial lever screw Removing the stitch cam guide plate assembly 68 Remove the screw and washer for the stitch dial 74 Remove the G carriage foot 69 Remove the two screws A for the stitch guide cam plate e Removing the latch stopper brush 70 Remove the two screws B for the stitch guide cam plate 75 Remove the latch stopper brush by loosening the screw 71 Remove the needle guide plate by loosening the two screws 76 Remove the arm for needle operation 72 Open the G carriage foot assembly and remove the stitch cam e Removing the stitch dial lever guide plate 77 Open the cover for the stitch dial lever and remove the spring Removing the following parts and the roller 73 The connecting plate the direction change plate R amp L and 78 Pull out the stitch dial and remove the screw and the stitch spring comes off at the same time dial lever 14 5 ASSEMBLING THE G CARRIAGE Names of Parts Latch stopper brush Screw for latch stopper brush 2 pes Arm for socket Spring for G needle socket 4 1 Stitch dial lever 4 2Stitch dial 4 3 Roller spring and cover 5 G carriage foot 6 Arm for needle operation e Mounting the latch stopper brush 1 Attach the right and left screws to the latch stopper brushes 4 2 Set the stitch dial to the stitch dial lever Mounting the arm for socket 4 3 Put the ro
30. ng hanger 3 Reader for needle selection Rubber 6 Spring hanger plate washer e Removing the G carriage feeding cam 43 Reader for needle selection assembly 44 Change lever for knitting needle assembly 45 G carriage feeding cam Pull out and remove all these three parts at the same time and remove the rubber washer located under the shaft of the reader for needle selection assembly Removing the G needle operation shaft 46 Remove the G needle swing cam spring 46 1 Remove the snap ring E 2 5 for the G needle operation shaft 47 Pull out the G needle operation shaft 48 Remove the G needle operation arm upper jj amp Spring hanger plate lower 4 Change lever for _ knitting needle 49 G carriage feeding cam 46 G needle swing cam 1 spring 46 1 Snap ring E 2 5 47 G needle operation shaft G needle operation arm G carriage feeding lever Presser plate for spring hanger Spring hanger plate upper Spring hanger plate lower Direction change lever spring Direction change lever Removing the G carriage feeding lever 49 Pull out the G carriage feeding lever 50 Presser plate for spring hanger 51 Spring hanger plate upper 52 Spring hanger plate lower 53 Direction change lever spring 54 Direction change lever Release the fit with the yarn feeder support assembly and pull them up at the same time Disassembling the G carriage Names of Parts Spring for retainer Re
31. not function smoothly Connecting plate assembly The direction change pawl is caught by the direction Tr change plate and the spring for the direction change plate E is not located properly Replace the direction change plate Clearance Yarn feeder change cam assembly R and L in this case i Direction change lever B assembly Direction change knob Surface to be planed Clearance Hole of upper plate assembly 35 5 The row counter functions heavily Adjust the longitudinal position of the row counter when the numeral rotor gets contact with the hole of the upper G carriage cover assembly and the counter functions heavily If the row counter connecting plate is bent adjust it to flat Apply oil or grease when the sliding part is out of oil and the counter functions heavily If it still functions heavily replace 6 The height and width of the extension rail are improper See the page 33 3 The carriage returns at any position where it does not normally retums The needle comes off at the position A Attach the needle 2 The needle of the position A is among needles where fabric hangs Knitting by automatic return is impossible 3 The needle of the position A is sometimes lowered Replace the needle or the needle retainning spring possible and it should be opened 5 5 mm or more by the spring Adjust or replace the G needle which is out of order as shown in the left figure Latch needle G needle
32. of Parts 1 Sensor body 2 Detecting bar 3 Snap ring for sensor 4 Sensor cover Microswitch Screw for sensor 2 pes When the two screws for the sensor for yarn breakage are loosened the DC cord and the cover comes off the body Assemble the sensor in the reverse order 9 TROUBLE SHOOTING 1 G carriage does not move 1 The G carriage does not move from the beginning 1 The motor does not run 1 Check to be sure that the power cord is connected with the outlet 2 Check to be sure that the pin plug is connected 3 Check to be sure that the detecting bar comes down 4 Check to be sure that the electric system is free from tester bar with the while wire of the DC cord and the minus side with the black wire When the tester indicates zero ohm replace the DC cord and the curl cord When the tester indicates ohm replace the power board When not zero ohm Replace the fuse and connect with the AC receptacle troubles Detach the pin plug from the G carriage and connect the part A with the plus side of the tester bar and the part B with the minus side with the tester set to the DCV range Check to be sure that the output voltage is within the range from 11V to 13V When the pin plug is not loaded with the output voltage Check the adaptor e Plug out from the AC receptacle Check to be sure that the fuse F101 is not burnt When the fuse is broken Set the tester to the ohm ran
33. of the lever kept upward 41 Attach the reader spring and the change lever spring for the Assemble so that the square hole of the operation lever for G change lever needle may locate in the shaft Assembling the G carriage 42 2 Right and left at two positions 42 ciu e Mounting the step feeder 42 1 Mount the step feeder onto the shaft of the G carriage plate without being touch with the lead wire of the DC motor Locate the select lever in the rear of the protruded part of the pattern selector cam 2 Let the shaft for reader and the change lever shaft through the step feeder 3 Put the carriage feeding lever into the cut part of the step feeder 42 2 Fix the step feeder with the right and left two screws Mounting the G needle operation cam 43 Keep the matching mark of the carriage feeding cam upward and match it with the mark of the G needle operation cam located on the periphery to put it in there is a mark of needle hole size in the inside of the outermost periphery of the cam 42 1 Step feeder 42 2 Screw for step feeder 2 pes G needle operation cam Yurn feeder change plate assembly Yarn feeder change cam spring Y b Screw for yarn feeder Longer pin Change cam spring Mounting the yarn feeder change plate assembly 44 Put the shorter pin of the yarn feeder change plate assembly into the groove of the yarn feeder change cam and put other pins into the yarn feeder holder assembly and the G needl
34. or yarn breakage it does not sometimes work If the yarn is cut after the sensor for yarn break age it securely works 1 Push the lever A of the sensor for yarn breakage to turn on the microswitch while connecting the tester with the pin plug If the tester indicates zero volt the sensor for yarn breakage is found normal In this case replace the mo tor control board If the tester does not indicates zero volt replace the sensor for yarn breakage Any abnormal sound is generated 1 Oil gets short between the bevel gear Z50 and the washer Replace the bevel gear Z50 and apply grease 2 The latch of the G needle gets contact with the gate pegs See the sections 3 2 and 3 3 3 The yarn feeder gets contact with the needle guide See the section 3 5 T a HQ
35. ounter does not function smoothly 8 Height and width of extension rail are improper 8 Bend to adjust Carriage returns at any 9 Needle comes off at position Attach needle position where it does not normally returns 10 Nee of position A is among needles where fabric gs 11 Needle of position A is sometimes es lowered lac e retaining See Manual KH Countermeasure Probable Cause Dropping stitches 1 G needle is out of order wW Replace G needle 2 Longitudinal vertical and lateral adjustments of 2 Adjust gate pegs gate pegs are bad a 3 Tilt of G needle isi improper 3 Bend and adjust G needle tilting lever assembly 4 Position of needle guide is bad 5 Movement of yarn feeder is improper 6 Vertical movement of latch presser and yarn feeder 6 Repair latch presser lever assembly and replace G is incorrect needle operation cam Stitches which are put 1 Reader for needle selection gets contact with the 1 Adjust the release hole of step feeder normally with the KH release hole of step feeder needle are made by the G needle 4 Bend and adjust needle guide 5 Adjust movement of yarn feeder 2 Reader does not smoothly move up and down 2 Replace upper plate assembly or apply grease 3 Rubber washer is not located onto the shaft G Resemble oo 4 Reader spring is not smoothly p
36. ow to check the stop reader for needle selection come off the guide holes switch Check whether the link for pitch adjuster comes off Set the tester to the fix with the washer and the tapping screw so that it ohm range x and ware may not come off connect the tester bars with the both ends of A The value of resistance is normally co When zero ohm replace the switch board which is out of order e 2 The 1 Disassemble and assemble the G carriage while checking these points and checking to be sure that each mechanism works smoothly G carriage stops in the middle of movement The G needle does not move due to knots stitch floats etc 3 The height and width of the extension rail is improper Adjust so that the needle bed may be parallel to the ex tension rail in the direction of the height and the width of the root part may be equal to the one of the bent part when installing the extension rail The yarn is entangled with the yarn take up device The G point cam of various types is floated and is not located at the proper position The needle of the machine comes forward the position B and gets contact with the G carriage Check these points c When the G carriage stops in the middle of the fabric Koot part Bent part move the G carriage out of the fabric according to the manual page 39 40 When the hook of the G needle is caught by the yarn feeder and is not pulled out se
37. parate the yarn feeder and the arm for socket where the G needle locates by force to pull out the G needle 3 The motor runs but the carriage does not move The G carriage feeding lever shaft is loosely assembled Turn over the G carriage If the shaft shown in the figure File the cut surface of the feed posi moves when the carriage is moved the assembly is found tioning plate teeth smooth when not loose In this case replace the G carriage plate assembly smooth The feed plate does not move smoothly and laterally See the page 34 The feed plate is aligned The direction change lever spring becomes weak The shaft of the casting off lever assembly comes off the hole of the upper plate assembly Replace or repair by checking these points Needle bed Extension rail 4 Pitch of the feed plate teeth is bad The feed plate teeth of which pitch is bad are not securely caught by the rack Replace Pin for carriage feed lever shaft 3 Lateral movement of feed plate oo Er 8 3 vu d ez Feed link lever E Direction change link R Direction change link L Feed positioning plate Rear rail auxiliary rack 34 2 The automatic return does not function 1 The carriage moves without return 2 The motor stops at the return position The direction The direction change knob functions heavily change pawl There is a difference in level between the upper G carriage should be
38. s located gets contact with the shaft of the contact assembly make the hole of the feed base assembly bigger When the reader for needle selection does not move smoothly and vertically replace the upper plate assembly that the following dimension may be obtained or apply grease when no spring is attached Reassemble if the reader for needle selection rubber is not put into the shaft of the contact assembly and is located under the operation lever assembly Replace the spring for retainer if damaged Spring for retainer Yarn feeder Needle guide aem reeder support Yarn feeder change plate pin B id Yarn feeder Moodie guide This part is damaged 2 The stitch knitted by G needle becomes the stitch by KH needle Replace the spring for reader if it is not smoothly put to the operation lever assembly 6 The vertical movement of the latch presser and the yarn feeder is improper 2 Repair if the lever of the change lever for stitch is not The abnormal sound might be generated The G needle operation cam is damaged by the warp of the latch presser lever Adjust the latch presser lever so that it may be right to the shaft Replace the G needle operation cam smooth and level This part should not be bent 3 Replace the change lever for stitch if it rotates at the shaft part against the lever 2 5 The stop key does not function and the row counter does not stop at 000 1 The
39. tainer for reader Washer for link Tapping screw 66 1 Pitch adjuster lever Link for pitch adjuster 7 Snap ring E 4 Snap ring E 3 Yarn feeder change lever Stitch adjusting plate DC motor 55 i 5d Screw for DC motor Feed change lever P Te 7 i 2 pcs e Removing the spring for retainer e Removing the yarn feeder change lever 55 Remove the spring for retainer and the retainer for reader 57 Remove the snap ring E 4 and the snap ring E 3 for the yarn over it feeder change lever Remove the yarn feeder change lever e Removing the link 58 The stitch adjusting plate comes off 56 Remove the washer and tapping screw for the link for pitch e Removing the DC motor adjuster 59 Remove the DC motor by loosening the two screws 56 1 Remove the pitch adjuster lever and the link for pitch When only DC motor is changed see How to replace the DC adjuster motor only page 27 Disassembling the G carriage Pitch adjuster ILL mm Screw for G needle m un cie operation arm 2 pcs 1 6D Screw for yarn feeder holder 5 pes Fa i b Yarn feeder unit 7 lt G needle swing arm m v Wi assembly lll 4 9 Pitch adjuster xe G needle operation arm Ers M base gt wu 3 r p 60 Spring for G needle socket C Screw for G needle m socket v a a Socket E Snap ring E 2 for G needle gg Stud E Arm
40. tch board the zero adjustment throughly How to check the start switch Connect the tester bars with the both ends of the connector Set the tester to the ohm range x and connect the and check the value of the motor resistance tester bars with the both ends of B When the tester indicates around two ohm the motor is The tester normally indicates c When zero ohm in the normal condition replace the switch board which is out of order When indicating other values replace the DC motor The tester indicates zero ohm when the start switch is pressed When not indicating zero ohm replace the switch board which is out of order 3 When no abnormality is found with the adaptor the DC Connector motor assembly and the switch board replace the motor control board The motor tries to run but the mechanism does not work 1 Check to be sure that the counter is not set to 000 2 Check to be sure that each knob is located inbetween 3 Check to be sure that the pin comes off the cam groove e Check whether the pin of the yarn feeder change plate assembly is in the both cam grooves Check whether the needle operation lever assembly and the operation lever for G needle assembly come off 2 Check the switch board the cam groove Set the row counter to Check whether the shaft of the casting off lever comes the numerals other than off the hole of the upper plate assembly 000 Check whether the shafts of the change lever and the H
41. ut to reader 4 Replace reader spring 5 ree lever for knitting needle is not smooth and 5 Adjust change lever level eve 6 Change lever rotates at shaft part _ 6 Replace c change lever Stitches which are put normally with the G needle are made by the KH needle 1 Distance between sensor and magnet is too far 1 Adjust motor control board longitudinally vertically and laterally 2 Switch for row counter does not operate smoothly 2 Replace row counter 3 Switch board is out of order _ 03 Replace switch board Sensor for yarn breakage 1 Microswitch for sensor for yarn breakage i is out of 1 Replace G89 G88 DC cord whole unit does not work order Abnormal sound is i 1 Oil is short between bevel gear Z50 and washer generated 2 Latch of G needle gets contact with gate pegs Stop key does not func tion and row counter does not stop working 1 Replace bevel gear Z50 and apply grease 2 Adjust gate pegs and G needle tilting lever assembly 3 Yarn feeder gets contact with needle guide 3 Adjust the movement of yarn feeder See Trouble shooting on page 36 See Trouble shooting See Disassembling the G carriage on page 6 See Trouble shooting on page 37 on page 37 See Trouble shooting on page 37 See How to adjust the G carriage on page 28 See Trouble shooting on pa
42. wire to the Check to be sure that the bevel gear can be rotated clockwise by upper plate assembly with the two binders and the one string hand Mounting the stop knob 54 1 Fix the plate with four snap rings E 59 Place the pattern selection knob so that the shaft of the 55 Fix the gear mount with the three screws selection lever may be pressed with it e Mounting the direction change lever B assembly e Mounting the aut return knob 56 Put the direction change lever B assembly into the yarn feeder 60 Place the aut return knob so that the lever for aut return of change cam with the pin kept upward and fix it with snap ring the step feeder may be located in the square hole of the knob EG Mounting the direction change knob Mounting the direction change lever A assembly 61 Place the direction change knob so that the boss may be 57 Put the direction change lever A assembly into the row coun located in the hole of the direction change lever A assembly ter connecting plate fit to the pin of the direction change lever B assembly and fix with snap ring E 24 Assembling the G carriage Names of Parts Switch key 62 Let the lead wire pass Swilch toig 3 por for each Screw 3 pcs Row counter window Row counter Screw 3 pcs carriage cover Screw for G carriage foot 2 pcs Snap ring E 3 Connector e Mounting the G canines cover Mounting the G carriage cover 1 Put the switch spr
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