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1200D SERVICE TRAINING MANUAL

1200D SERVICE TRAINING MANUAL. TABLE OF CONTENTS. 1200D GAUGE. FRONT COVER REMOVAL. 1. Remove the two 2.5 hex screws. The bottom hex screw you will be able to remove with the thread guide.

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1200D SERVICE TRAINING MANUAL

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  1. 1200D SERVICE TRAINING MANUAL

  2. TABLE OF CONTENTS

  3. 1200D GAUGE

  4. FRONT COVER REMOVAL 1. Remove the two 2.5 hex screws. The bottom hex screw you will be able to remove with the thread guide. 2. Gently start to remove the take up lever cover by lifting up on it. Be careful not to rip out the take up lever spring. Also be careful not to bend the take up lever. 3. Remove the pattern selector dial by pulling it off gently. 1.

  5. 4. Use the key ring to remove the white cap without damaging it and loosen the philips head screw on the inside. 5. Remove the screw that holds the thread guide plate behind the looper cover door and the screw to the left of it. 6. Using a small flat head screw driver, gently push up on the white cap that is on the tension release lever, and remove it. 2.

  6. 7. Turn the hand wheel towards you to lower the take up lever so that the top portion is within the opening of the front cover. 8. Grab the front cover from the top and start to move it over the thread tension release lever and over the top portion of the take up lever. 9. Turn the hand wheel backwards to raise the take up lever and continue to remove the front cover until it is free from the take up lever. 10. Gently lift the front cover around the chain looper tension dial, and remove the front cover. 3.

  7. REAR COVER REMOVAL 1. Using the small key ring, remove the 3 white caps. Remove the screws that are inside the holes completely. 2. Gently lift up on the rear cover and lift it over the pressure foot dial. 3. Start to remove the rear panel by taking it from the right and gently moving out and towards the left. 4. As you remove the cover be careful of the machine socket unit and switch. 4.

  8. INSIDE COVER REMOVAL 1. Remove the screw that holds the thread guide behind the looper cover door. 2. Remove the two screws that holds the chain looper take up lever cover. 3. Remove the inside cover. 5.

  9. BASE COVER REMOVAL 1. Remove the 4 screws that hold the base to the bottom of the machine. Do not remove the cushions. 2. Remove the base plate and looper cover door. 6.

  10. ADJUSTING PRESSER BAR HEIGHT 1. Raise the presser foot and place the 1200D gauge underneath the foot lengthwise. The curved part of the gauge should be at the front tip of the foot. It is necessary to lift up on the foot slightly in order to place the gauge it underneath. The pressure dial on top should be set to 5. 2. Remove the two screws that hold the light bulb bracket on. 3. Locate the 2mm hex that holds the presser bar unit. If the presser bar needs to be adjusted, loosen the hex screw. Lower the presser bar or raise it until it sits on top of the gauge. Make sure not to turn the presser bar or else the foot alignment will be off. When finished tighten the screw. 7.

  11. ADJUSTING NEEDLE BAR HEIGHT 2. After raising the needle bar to the highest position, take the 1200D gauge and place it under the R1 needle. The tip of the needle should be either right on top of the gauge or slightly below. The measurement from the needle plate to the tip of the needle is 12mm +/- . 2mm. 1. Remove the presser foot. Place a new needle into spot R1. Remove any other needles that may be in the needle bar. Raise the needle bar to the highest position. 3. If an adjustment is needed, locate the 2.5mm hex screw. Loosen the screw and either raise the needle bar up or down to the proper position. Do not rotate the needle bar or the alignment with the foot and plate will be wrong. 4. Reattach the light bulb bracket and insert the two screws. 8.

  12. LOWER LOOPER HEIGHT 1. Locate the lower looper and look on the right hand side of the looper arm. There are two 2mm hex screws that secure the needle guard. Loosen the two 2mm screws using an allen key in order to push the needle guard towards the machine and away from the lower looper. 2. Turn the hand wheel towards yourself to bring the looper to its most right swing. Place the 1200D gauge on the looper arm shaft and bring it straight up to the tip of the looper. The tip of the lower looper should line up with the first step at the top of the vertical standing gauge. The measurement is 65mm. 3. If it is at an incorrect height, loosen the 2mm hex screw on the lower looper arm and either move the looper up, or down to the 65mm position. When done, tighten the screw. 65mm 9.

  13. LOWER LOOPER CLEARANCE 1. Place a second needle into the R2 spot. Remove the needle plate. 2. Turn the hand wheel towards you and lower the needle bar to bring the lower looper right behind the R1 & then R2 needles. The lower looper should pass right behind the needles without hitting, or without to much space. It should clear at about .05mm which is almost zero. 3. If an adjustment is needed, loosen the 3mm screw from the bottom of the lower looper arm shaft slightly. Just break the screw and do not loosen too much. 4. Gently move the looper, or tap with a tool to get the desired measurement. When .05mm has been reached tighten the 3mm screw. 10.

  14. ANGULAR POSITION OF LOWER LOOPER 1200D GAUGE 1. Turn the hand wheel towards you to bring the lower looper to its far left swing position. 2. The distance between the tip of the lower looper and the left side of needle R1 should be about 2.6 – 3.1mm. Take the 1200D gauge and hold the tip of the narrow end into the space to use as a width gauge. 3. If an adjustment needs to be made, loosen the 3mm screw on the bottom of the lower looper arm very slightly, and do not move the lower looper arm in and out. The looper should only be moved left and right to obtain the correct distance. When finshed with the adjustment tighten the 3mm screw and check lower looper clearance(pg.10). 11.

  15. NEEDLE GUARD CLEARANCE 1. Turn the hand wheel towards you and bring the needle bar to it’s lowest position. 2. Move the needle guard towards the needles or away to obtain a .05 clearance. 3. Hold the guard in position and tighten the two 2mm hex screws. 12.

  16. LOWER LOOPER TIMING 1. Turn the hand wheel towards you to bring the tip of the lower looper to the left side of needle R1. The tip should hit above the eye of the needle about 2mm. Mark this spot. 2. Continue to turn the hand wheel towards you to bring the needle all the way to the right and continue back to the left. Stop once the tip of the lower looper ends up on the left hand side of needle R1. The tip of the lower looper should be the same as when it passed by on its initial movement. If the looper swing is not identical, an adjustment needs to be made. ALWAYS TURN THE HANDWHEEL TOWARDS YOU TO CHECK. NEVER BACK AND FORTH. 3. Locate the lower looper eccentric cam from the bottom of the machine. Loosen both 2mm hex screws and hold the cam with your hex driver. If the right to left swing is in a lower position to the needle eye, turn the hand wheel counter clockwise. If the left to right swing is in a lower position to the needle eye, turn the hand wheel clockwise. Tighten both the screws. Turn the hand wheel several times and recheck the timing positions. 13.

  17. ANGULAR POSITION OF UPPER LOOPER • Make sure that there is no play on the upper looper arm and inspect the upper looper for burrs or scratches or a dull point. Bring the upper looper to it’s far left swing position. Take the 1200D gauge and hold it lengthwise so that the tip of the gauge touches the R1 needle, and the tip of the upper looper is on the first step. The distance between the tip of the upper looper and the R1 needle should be 5.2 - 5.6mm. 2. If the distance is wrong, locate the 3mm hex screw from underneath the machine on the upper looper drive arm. Loosen the screw in order to move the upper looper arm. 3. Grab the upper looper arm and move it on its arc forward or back to obtain the correct measurement. Once the correct position has been made, tighten the 3mm hex screw from below. 14.

  18. UPPER & LOWER LOOPER TIMING 1. Bring the upper looper to its lowest position, than raise it until the tip of the looper is even with the bottom edge of the lower looper Sample #1 Sample #2 Wrong 2. The tip of the upper looper should be between .2 to 1.2 mm to the left of the eye of the lower looper. 3. If an adjustment is needed, loosen the 2 hexagon screws (2.0mm) on the upper looper drive cam and turn the cam: Away from you if the loopers look like sample #1. Toward you if the loopers look like sample #2. 15.

  19. UPPER LOOPER CLEARANCE 1. If the clearance between the upper looper and lower looper is incorrect, broken needles, thread or skipped stitches could occur. The upper looper should pass behind the lower looper with a clearance of .05 mm. 2. If an adjustment is needed, loosen the 2.5mm hex at the top of the upper looper shaft arm. 3. Grab the upper looper arm and pivot left to right to get the desired clearance. While holding the looper tighten the 2.5mm screw. 16.

  20. ANGULAR POSITION OF CHAIN LOOPER Chain looper in far right position and needle L2 inserted. 1. Place a new needle into L2 position. Turn the hand wheel towards you to bring the chain looper to the far right position. 3.If an adjustment is needed, loosen the 3mm hex screw slightly at the bottom of the chain looper arm, and move the looper arm into position. Then tighten screw. Be sure to check the clearance after this adjustment. 2. The distance between the chain looper and the L2 needle should be about 1.5 – 1.8mm. It is the thickness of the 1200D gauge. 17.

  21. CHAIN LOOPER TIMING • Place a new needle into the L0 position. Turn the hand wheel towards you to move the chain looper to the far right position. • **Notice as you start to turn the hand wheel towards you, when the chain looper starts to move to the left the needle bar will start it’s movement upward simultaneously.** 2. As you turn the hand wheel towards you and the needle starts it’s upward movement stop when the looper eye is behind the needle eye. They should match up. 3. If an adjustment is needed, loosen the same eccentric cam as the lower looper, and move the eye into position. If it is necessary to do this, it will only be a small movement. Moving the cam could offset the lower looper and the lower looper timing must be checked again. 18.

  22. CLEARANCE OF CHAIN LOOPER 1. There should be a needle in the L0 and the L2 positions. Turn the hand wheel towards you to bring the chain looper to the far right. Continue to bring the chain looper back to the left and stop once the tip of the chain looper is behind the L2 needle. The clearance between the looper and the needle should be .05mm. 2. Continue to bring the chain looper to the left and behind the L0 needle. The clearance should be .05mm as well. 3. If an adjustment is needed, loosen the 3mm hex screw slightly. Move the looper arm in or out to get the desired clearance. Careful not to move the looper left to right. Tighten the screw. Check the angular position of the chain looper again. 19.

  23. CLEARANCE OF CHAIN LOOPER NEEDLE GUARD 1. Turn the hand wheel towards you to bring the chain looper, in it’s right to left movement, to the right hand side of the L2 needle. The clearance between the looper needle guard and the needle should be less then .01mm. 2. If an adjustment is needed, locate the top screw on the chain looper arm. This screw has a spring behind it. When it is turned slightly clockwise the guard will move closer to the needle, and counter clockwise will move the guard farther from the needle. 3. The distance between the tip of the looper down to the guard should be about 1mm - 2mm +/- .02mm. If an adjustment is needed loosen both screws and move the chain guard up or down for the correct distance. 20.

  24. ORBITAL TIMING OF CHAIN LOOPER 1. Install a needle into the R1 position and install the needle plate. The orbital timing is the path that the chain looper takes as the hand wheel is turned toward you. It travels behind the needles and then in front without hitting. 2. Turn the hand wheel towards you to bring the needle down towards the needle plate. Stop once the top part of the needle eye has become flush with the needle plate. At this point the eccentric cam on the bottom has a mark on it and it should be lined up with the crease in the chain looper driver. 3. If an adjustment is needed loosen the two 2mm hex screws. Move the eccentric cam to line up the mark on the eccentric cam with the crease on the looper driver. 21.

  25. LOWER LOOPER & CHAIN LOOPER ENGAGEMENT 1. Turn the hand wheel towards you to bring the lower looper to the right. Push down on the lower looper easy thread lever. As you continue to turn the hand wheel towards you the looper will move to the left. When it reaches it’s far left position, the easy thread lever will hit a kick plate and disengage. 2. When the lower looper is to the far left, the chain looper will be to the far right. Push up on the lever to disengage the chain looper. When the chain looper continues to move and it reaches it’s far left position the lever will hit the same kick plate as the lower looper lever, and will engage the chain looper again. 3. If an adjustment is needed locate the kick plate underneath the feed dog system. Loosen the screw and move it forwards or backwards as well as left to right to get the proper engagement and disengagement of the levers. 22.

  26. FEED DOG HEIGHT & GAP DF SL 1.3mm 1. Replace the needle plate, and the presser foot. Set the stitch length to .5 and the differential feed to 1. Turn the hand wheel towards you to bring the feed dogs to their highest position. Place the 1200D gauge over the left side of the feed dogs lengthwise. Lower the presser foot on top of the gauge. The height of the feed dogs should be 1.3mm. 2. Locate the 2mm screw behind the left rear end of the needle plate. This screw locks the adjusting screw which is to the right hand side. 3. It will be easier to adjust the screw from behind the machine. Turn the screw left or right to raise or lower the feed dogs to the 1.3mm height. 4. Remove the presser foot. The distance between the front and back feed dogs should be 2.7mm – 3.2mm. If it is not, take the 1200D gauge and place in between the two feed dog sets. Loosen the 2mm hex screw and move the plate to get the correct distance. Tighten the screw. 23.

  27. CUTTER & VERTICAL FEED TIMING 1. Make sure that there is a needle in the R1 position. When the needle bar is at it’s highest point the cutter should be as well. When the needle bar starts it’s movement downward the cutter should move simultaneously. 2. If the needle bar and the cutter are not moving at the same time an adjustment will need to be made. Lower the needle bar all the way down and start to bring the needle back up. Stop when the eye of the needle is sitting right above the surface of the needle plate 3. If an adjustment is needed, locate the eccentric cam for the cutter from underneath the machine. There is a mark on the cam and it should be in line with the crease on the cutter driver arm. There is a +/- .5mm tolerance for this adjustment. If needed to move loosen the two 2mm screws on the cam and move into position. Hex screws on cam for adjustment 24.

  28. HORIZONTAL FEED TIMING This is a very important adjustment. This adjustment will prevent the chain needles from bending or breaking when sewing though maximum thickness levels. DF SL 1. Place a needle in the L0 position. Place the presser foot on and a piece of paper underneath the foot. Set the Differential feed to 1 and the stitch length to 4. 2. Turn the hand wheel towards you to bring the needle into the paper all the way. Continue to turn and stop as soon as the needle raises right above the paper. 3. Turn the hand wheel backwards to bring just the tip of the needle into the paper again. Then turn forward to quickly bring the needle out again. You should see a small hole in front of the bigger needle hole. The smaller hole is in the middle as well. This is the correct position. 25.

  29. 4. If an adjustment is needed, locate the eccentric cam to the right of the hand wheel underneath the machine. Loosen the 2mm screw on the eccentric cam and hold the cam still with your hex tool. Turn the hand wheel either clockwise or counter clockwise in order to get the correct setting. 26.

  30. DIFFERENTIAL FEED TIMING 1. Set the differential at 1 and the stitch length at 5. The front and back feed dogs should move evenly throughout the entire motion. If they are not moving evenly together turn the stitch length to .05 DF SL 2. Lay the machine on it’s back and located the black collar which is connected to a lever from your differential feed dial. Use a 2mm hex to loosen this screw. 3. Use the 1200D gauge and bring it to the left side of the machine. Locate the differential crank. Now that the screw is loosened the crank can be moved. Place the gauge against the block and move the crank so that it lines up with the back end of the curved part of the gauge. Then tighten the screw. The distance when the differential is set to .05 and stitch length to 5 should be 12mm – 12.3mm. Turn the differential dial back to 1 and check to see if the front and back are moving together. 12mm-12.3mm 27.

  31. POSITION OF FIXED CUTTER & WIDTH DIAL 1. Turn the fixed cutting dial to 1 in order to get the proper set up position for the fixed cutting blade. 2. The distance between the fixed cutting blade and the needle plate should be.2-.3mm 3. If an adjustment needs to be made, locate the two screws under the fixed cutter dial. Loosen the screws and move the dial plate in order to get the correct distance. 4. When moving the dial plate, it pushes against the fixed cutting system and will either decrease the distance or increase the distance between the fixed cutter and the needle plate. 28.

  32. ADJUSTMENT OF AUTOMATIC TENSION UNIT 1. Set the stitch pattern to program 1 for four thread. Make sure that all the tension dials are set to “N” position. 2. If you have a tension gauge use a 50 weight cotton thread. The following list are the tension values for the four threads. Yellow Tension : 50 to 60 gr. Blue Tension : 35 to 45 gr. Red tension : 10 to 15 gr. Green tension : 20 to 25 gr. 3. If the tensions need to be adjusted, gently use a small flat head to turn the fine tuning dials to the left of the tension dial. 29.

  33. POSITION OF TENSION CAM AND PATTERN SELECTION DRUM 1. If the automatic tension is not correct, it will be necessary to check the cam position. Turn the pattern selection to 1. At this point, locate the tension cam to the far left of the yellow tension unit. There is a raised mark that is on the cam. This notch should be in line with the bump on the tension cam lever. 2. If an adjustment is needed, locate the bottom tension flywheel. 3. After loosening the 2mm hex screw, turn the cam in order to reset the top tension cams. Once you have lined up the mark with the tension cam lever, tighten the screw. 30.

  34. 4. When the front cover is on the pattern selector should be even with the display window. 5. If it is not, use a 2mm hex screw driver and loosen the 2mm hex screw and turn the pattern drum to make it even with the display window. 31.

  35. UPPER LOOPER SHIFTING CAM When the machine pattern selection is turned to 10, the upper looper should be disengaged. 1. Turn the pattern selection to #1 (four thread). When the pattern dial is turned to #10 the upper looper should be locked down as it goes into it’s lowest position. 2. If the upper looper is not disengaging, lower the needle bar to it’s lowest position. Make sure the pattern dial is on # 10. Loosen the 2mm hex screw on the upper looper shifting cam. Rotate the cam until the black hook follower falls into the hollow on the cam. Tighten the screw. Upper looper unlocked position View from underneath the machine Upper looper locked position 32.

  36. REAR COVER REPLACEMENT 1. Place the rear cover on the machine starting from the right side. Fit the cover over the machine socket unit and switch. 2. Bring the rest of the cover towards the left side and gently lift up on the cover to make it over the pressure dial. 3. Replace the three screws and the white caps. Two out of the three caps are the same and have a special shape for the rear cover. 33

  37. FRONT COVER REPLACEMENT 1. Put the take up lever in the middle position. Take the front cover and slip it over the top of the take up lever. 2. Lift up on the cover while turning the hand wheel to fit the take up lever back in. Also lift the cover over the thread tension release lever. Be careful not to bend the take up lever. If you did, gently bend it back into position. 3. Tighten the screw on the right hand side. 34.

  38. 4. Place the lower thread guide on and place the screw in and tighten very loosely. 5. Place the thread take up lever cover on by, first placing it around the bottom hex screw and thread guide. Be very careful of the check spring and place it within the opening of the cover. Lock the left side in and tighten the two 2.5 hex screws. 6. Place the tension release cap back on and the white cap and stitch selector on the right hand side. 35.

  39. BASE COVER REPLACEMENT 1. Place the base on and reattach the four base screws. Make sure that the left side door is open. 36.

  40. POSITION OF UPPER LOOPER THREAD TAKE UP LEVER 1. Locate the upper looper thread take up lever. If the take up lever is not in the proper position, skipped stitches or looping of the thread could occur. 2. Turn the hand wheel towards you to bring the take up lever to it’s highest position. Take the 1200D gauge and stand the curved part on the base cover and hold it vertical to the top part of the take up lever. The distance should be 46 – 47.3mm. *The little notch on the gauge represents 47.3mm.* 47.3mm 3. If it is at the wrong height , loosen the screw and adjust it accordingly. 37.

  41. INSIDE COVER REPLACEMENT 1. The upper take up lever must be in the middle position. Be careful of the spring on the take up lever. 2. Place the inside cover back into it’s spot. Place the thread guide on and insert the screw. 3. Replace the chain looper cover plate and the two screws. 4. Place the thread guide back on and insert the two screws back into the front panel. 38.

  42. ADJUSTMENT OF THE TOP COVER DEVICE TOP COVER HOOK ROUND THREAD GUIDE ONLY TIGHTEN R2 SCREW R FOOT 1. Remove any needle from R1 & R2. Insert needles into L0 and L2. Insert the blue R foot. Insert the top cover hook and tighten with the 1.5 hex screw. Place the needle plate back on the machine. Take the round thread guide and isert it into the R1 and R2 spot. Only tighten the R2 screw in order to get a correct stitch and a correct adjustment reading. 2. Lower the triangle thread guide. 39

  43. 3. Turn the hand wheel towards you to bring the top hook cover in front of the L0 needle. Line up the tip of the hook with needle L0. 4. There should be a 1mm distance between the L0 needle and the tip of the top cover hook. 5. If the clearance is not 1mm, locate the 1.5 hex screw on the back of arm that holds the top cover hook. Loosen the 1.5 screw that holds the top cover hook and from behind the black arm, either tighten or loosen in order to move the top cover hook closer or farther from the needle ADJUSTING SCREW LOOSEN 1.5 SCREW 40.

  44. 6. Turn the hand wheel towards you to swing the top cover hook to it’s far right position. The right edge of the round thread guide should be even with the right edge of the triangle thread guide. RIGHT EDGES EVEN 7. If the round thread guide and the triangle thread guide edges are not even, locate the silver plate on the left side of the machine. Insert the 2mm hex driver through the metal plate and into the black collar to loosen the 2mm hex screw. Move the triangle guide so it will be even with the round thread guide. Then tighten the screw. 41.

  45. 8. The tip of the top cover hook should be sticking out from underneath the triangle thread guide about 1mm. 9. If an adjustment needs to be made, use a pair of pliers to pull down on the spring arm that is connected to the ball joint. 10. Turn the spring arm in 180 degree increments to change the position of the top cover hook point. Clockwise to bring the hook to the right. Counter clockwise to bring the hook to the left. 42.

  46. 11. Use a pair of pliers to reattach the spring arm into the ball joint and test to see if the tip of the top cover hook is sticking out from underneath the triangle thread guide. 3mm 12. The distance between the top cover hook to round thread guide should be 3mm. If it is not, reshape the thread guide untill 3mm is set. 43.

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