AVL Looms Jacq3G User manual

Jacq3G Loom User’s Manual
AVL Looms
2360 Park Avenue
Chico, CA 95928-6785
U.S.A.
530 893-4915
530 893-1372 fax
[e-mail]
www.avlusa.com
Version 1
November 2019

Jacq3G Loom User’s Manual Introductory Information
Page | i
Introductory Information ................................................................................................................ 1
Safety .......................................................................................................................................... 2
Introduction ................................................................................................................................. 4
Loom Features ............................................................................................................................ 4
About this manual ....................................................................................................................... 7
Loom Orientation ........................................................................................................................ 8
Jacq3G Loom Parts ..................................................................................................................... 8
Tools Needed For Assembly ..................................................................................................... 13
Bolt And Nut Hints ................................................................................................................... 14
Before Assembly ....................................................................................................................... 17
Assembling the Loom ................................................................................................................... 19
Side Frames ............................................................................................................................... 20
Assembly of the Module Frame ................................................................................................ 23
Install the Lower Front Assembly............................................................................................. 27
Connect Side Frames to Module Frame.................................................................................... 27
Add the Data Cable Guide ........................................................................................................ 29
Add the Lower Back ................................................................................................................. 29
Install the Modules .................................................................................................................... 29
Finish connecting the frame ...................................................................................................... 33
Squaring the Completed Frame ................................................................................................ 34
Add the Warp Beams .................................................................................................................... 37
Warp Beams .............................................................................................................................. 38
Install the Lower Warp Beam ................................................................................................... 38
Install the Upper Warp Beam ................................................................................................... 40
Installing the Separation Roller ................................................................................................ 41
Tension Arm Installation .......................................................................................................... 41
Install the Cloth Storage System ................................................................................................... 51
Installing the Cloth Beam ......................................................................................................... 52
Cloth Storage System ................................................................................................................ 53
Install the Beater ........................................................................................................................... 63
Bottom Swing Beater ................................................................................................................ 64
Overhead Beater (optional equipment) ..................................................................................... 72
Overhead Single-Box Flyshuttle Beater Tie-Up (optional equipment) .................................... 84
Overhead Multi-Box Flyshuttle Beater (optional equipment) .................................................. 85

Introductory Information Jacq3G Loom User’s Manual
Page | ii
Vertical Pull Flystring Tie-Up .................................................................................................. 88
Two-Box Flyshuttle – Dropbox Movement .............................................................................. 91
Four-Box Flyshuttle Dropbox Movement ................................................................................ 93
Assemble the Bench ...................................................................................................................... 97
Assemble the bench .................................................................................................................. 98
Connect the Lift System.............................................................................................................. 101
AVL Jacq3G E-Lift II Installation .......................................................................................... 102
Installing an Air Lift ............................................................................................................... 110
Using the Jacq3G Loom.............................................................................................................. 115
Introduction To The Loom Systems ....................................................................................... 116
Warp Density Adjustment Assembly...................................................................................... 127
Shed Operation........................................................................................................................ 135
E-Lift Operation ...................................................................................................................... 136
A-Lift Operation ..................................................................................................................... 137
Steps For Initial Set-Up .......................................................................................................... 138
Procedure For Warping ........................................................................................................... 140
Using the Jacqpoint Software ................................................................................................. 140
Lubrication .................................................................................................................................. 143
Lubrication Schedule .............................................................................................................. 144
Lubricant Types ...................................................................................................................... 144
Places to use Dry Lubricant: ................................................................................................... 145
Places to use Grease: ............................................................................................................... 150
Troubleshooting .................................................................................................................................. 151
Troubleshooting ...................................................................................................................... 152
Equipment Tests...................................................................................................................... 152
Equipment Fixes ..................................................................................................................... 154
The Fine Print ............................................................................................................................. 165
AVL Customer Service ........................................................................................................... 166
AVL Warranties ...................................................................................................................... 166
Notice to Users in the European Union .................................................................................. 168
List of Figures
Figure 1 - Jacq3G - Full View ........................................................................................................ 9
Figure 2 - Jacq3G - Full View ...................................................................................................... 11
Figure 3 – Tools needed for assembly .......................................................................................... 13
Figure 4 - Hex Bolt ....................................................................................................................... 14

Jacq3G Loom User’s Manual Introductory Information
Page | iii
Figure 5 - Carriage Bolt ................................................................................................................ 14
Figure 6 - Flat Head Machine Screw ............................................................................................ 14
Figure 7 - Flat Washer .................................................................................................................. 15
Figure 8 - Hex Nut ........................................................................................................................ 15
Figure 9 - Square Nut .................................................................................................................... 15
Figure 10 - Wing Nut .................................................................................................................... 15
Figure 11 - Allen Wrench ............................................................................................................. 15
Figure 12 – Socket Head Cap Screw (SHCS) ............................................................................... 15
Figure 13 - Measuring Bolts ......................................................................................................... 15
Figure 14 – Nut access hole .......................................................................................................... 16
Figure 15 - Footprint of Wood Frame and Module Frame ........................................................... 17
Figure 16 - Right Side Frame Assembly, inside view .................................................................. 21
Figure 18 - Loom footprint ........................................................................................................... 23
Figure 19 - Initial Assembly Layout ............................................................................................. 24
Figure 20 - Arrangement of Module Frame Pieces for Assembly ................................................ 25
Figure 21 - Orientation of Side Frame to Upper and Lower Assemblies ..................................... 25
Figure 22 - Orientation of Side Frame Bars at Upper and Lower Assemblies ............................. 26
Figure 23 - Areas for grasping the Module Frame during the lift ................................................ 26
Figure 24 - Wood and Module Frames with Connecting Bolts .................................................... 28
Figure 25 - Position for Securing Axle prior to Module Installation ............................................ 30
Figure 26 - Routing the Module Cables ........................................................................................ 31
Figure 27 - Connection of Cables and Securing them to the Module Frame ............................... 33
Figure 28 - Completed Module and Wood Frames ...................................................................... 34
Figure 29 - Beam Retainer ............................................................................................................ 39
Figure 30 - Warp Beam Handle .................................................................................................... 40
Figure 31 - Lower Warp Beam Tension ....................................................................................... 42
Figure 32 - Tension Arm Bolt ....................................................................................................... 43
Figure 33 - Lower Beam Tension Cord ........................................................................................ 44
Figure 34 - Upper Position Tension .............................................................................................. 45
Figure 35 - Tension Cable around Brake Drum ............................................................................ 46
Figure 36 - Upper Tension Tie-up ................................................................................................ 47
Figure 37 - Weight with wooden bracket removed ...................................................................... 48
Figure 38 - Tension Arm with Weight .......................................................................................... 48
Figure 39 - Cloth Beam Assembly................................................................................................ 52
Figure 40 - Right Side Cloth Beam Support ................................................................................. 53
Figure 41 - Pressure Roller Bracket .............................................................................................. 54
Figure 42 - Pressure Roller and Cloth Beam on Loom ................................................................. 55
Figure 43 - Cloth Storage System Rollers .................................................................................... 56
Figure 44 - Cloth Take-up Drum .................................................................................................. 57
Figure 45 - Cloth Storage Drum ................................................................................................... 57
Figure 46 - Routing the Cloth Take-up Cord ................................................................................ 59
Figure 47 - Knot on Cloth Take-up Drum .................................................................................... 60
Figure 48 - Cloth Storage Apron .................................................................................................. 61
Figure 49 - Beater Bumper Block ................................................................................................. 64
Figure 50 - Beater Support ............................................................................................................ 65
Figure 51 - Bottom Swing Beater Support ................................................................................... 66

Introductory Information Jacq3G Loom User’s Manual
Page | iv
Figure 52 - Beater Leg .................................................................................................................. 67
Figure 53 – Beater Top and Reed ................................................................................................. 68
Figure 54 - Single-box Flyshuttle Beater ...................................................................................... 69
Figure 55 - Beater Reed Support .................................................................................................. 70
Figure 56 - String tie-up and handle ............................................................................................. 71
Figure 57 - Axle Block on loom ................................................................................................... 73
Figure 58 - Beater Retainer ........................................................................................................... 73
Figure 59 - Beater Retainer ........................................................................................................... 74
Figure 60 - Beater Pivot Base ....................................................................................................... 74
Figure 61 - Overhead Beater ......................................................................................................... 75
Figure 62 - Overhead Beater Uprights .......................................................................................... 76
Figure 63 - Mount hanging arms .................................................................................................. 77
Figure 64 - Place Hanging Arms on Loom ................................................................................... 78
Figure 65 - Beater Axle................................................................................................................. 79
Figure 66 - Push Arms and Tilt Arms ........................................................................................... 79
Figure 67 - Racking the Overhead Beater..................................................................................... 81
Figure 68 - Beater Return Spring Assembly ................................................................................. 82
Figure 69 - Beater Reed Support .................................................................................................. 83
Figure 70 - String tie-up and handle ............................................................................................. 85
Figure 71 - Vertical Pull Upper Pulley Assembly ........................................................................ 86
Figure 72 - Drop Box Assembly from Rear.................................................................................. 86
Figure 73 - Flyshuttle Box from back ........................................................................................... 87
Figure 74 - Flyshuttle on cord ....................................................................................................... 88
Figure 75 - knot on flyshuttle cord ............................................................................................... 89
Figure 76 - Routing Flyshuttle Cord ............................................................................................. 90
Figure 77 - Spring and washer on Flyshuttle cord ........................................................................ 90
Figure 78 - Flyshuttle adjustment screw ....................................................................................... 92
Figure 79 - Flyshuttle Turnbuckle ................................................................................................ 93
Figure 80 - 4-box Shift Handle Cable to Drop Box ...................................................................... 94
Figure 81 - 4-box Flyshuttle Beater Shift Handle ......................................................................... 95
Figure 82 - Bench (shown with Tool Bag - optional) ................................................................... 98
Figure 83 - E-Lift parts installed (Main Drive Sprocket not visible) ......................................... 103
Figure 84 - Chain with Connecting Parts .................................................................................... 104
Figure 85 - Chain with Connecting Link partially inserted ........................................................ 105
Figure 86 - Chain with Link End and Link Clip in place ........................................................... 105
Figure 87 - Closing the Connecting Link Clip with Pliers ......................................................... 106
Figure 88 - Main Drive Sprocket with motor and chain (Interior View) .................................... 107
Figure 89 - Interior of Control Box, connection for E-Lift Motor .............................................. 108
Figure 90 - Air Lift cylinders on loom........................................................................................ 112
Figure 91 - A-Lift Foot Pedal ..................................................................................................... 113
Figure 92 - FRL Detail (may vary) ............................................................................................. 114
Figure 96 - Control Box, Side 1 (Showing Vents, Power Switch and Power Source) ............... 117
Figure 97 - Control Box, Side 2 (Showing Module Data Cable Plugs –CAT5) ......................... 118
Figure 98 - Control Box Side 3 (Showing Driver Board Power Cable Plugs) ........................... 118
Figure 99 - Control Box, Side 4 (Showing E-Lift and Computer Connections) ........................ 119
Figure 100 - Control Box, Top (Showing Cautionary Note) ...................................................... 119

Jacq3G Loom User’s Manual Introductory Information
Page | v
Figure 101 - Numbered hooks on modules ................................................................................. 120
Figure 102 - Module, front.......................................................................................................... 121
Figure 103 - Module detail, front ................................................................................................ 122
Figure 104 - Module, back .......................................................................................................... 123
Figure 105 - Module detail, back ................................................................................................ 124
Figure 106 - Module detail, back, solenoid assembly ................................................................ 125
Figure 107 – Module, Front, Driver Board ................................................................................. 126
Figure 108 – Modules, front view showing board lights ............................................................ 127
Figure 109 – Upper and Lower Dial-A-Sett Assemblies ............................................................ 129
Figure 110 – Dial-A-Sett, lower right assembly ......................................................................... 130
Figure 111 – Dial-A-Sett, lower detail ....................................................................................... 131
Figure 112 - Dial-A-Sett, lower assembly .................................................................................. 131
Figure 113 - Dial-A-Sett, Upper right assembly ......................................................................... 132
Figure 114 - Dial-A-Sett, upper detail ........................................................................................ 133
Figure 115 - Dial-A-Sett, upper assembly, rear view ................................................................. 133
Figure 116 - Dial-A-Sett, upper assembly, front view................................................................ 134
Figure 117 - Dial-A-Sett, upper assembly .................................................................................. 134
Figure 118 - Dry Spray Lubricant (RZ-50) ................................................................................. 144
Figure 119 - Clear Grease (Tri-Flow) ......................................................................................... 145

Jacq3G Loom User’s Manual Introductory Information
Page | 1
INTRODUCTORY
INFORMATION

Introductory Information Jacq3G Loom User’s Manual
Page | 2 Safety
SAFETY
Before Getting Started:
Please read the entire manual before using the loom.
Warnings:
WARNING:
EQUIPMENT SHOULD ONLY BE USED FOR TEXTILE MANUFACTURING. IF
THE EQUIPMENT IS USED IN A MANNER NOT SPECIFIED BY THE
MANUFACTURER, THE PROTECTION PROVIDED BY THE EQUIPMENT MAY
BE IMPAIRED.
WARNING:
ELECTRICAL SHOCK HAZARD. DO NOT TAMPER WITH ELECTRICAL WIRES
OR OPERATE THE LOOM WITH SAFETY PANELS OPENED OR REMOVED.
WARNING:
PINCH, CRUSH, AND FINGER CUT-OFF HAZARDS. DO NOT OPERATE THE
LOOM WITH SAFETY PANELS OPENED OR REMOVED. DO NOT PLACE
HANDS IN MOVING MECHANISMS OR SCISSORS.