HIGHLEAD HLK-03 User manual

HLK-03
Electronic Direct Drive Bar Tacker Machine
Instruction Manual
Parts Catalog
S
HANGHAI BIAOZHUN HAILING SEWING MACHINERY CO., LTD
.

This technical manual explains the instructions how to operate and maintain the sewing
machine．All information in this technical Manual are subject to change without notice．
ShangHai HuiGong CORPROTATION has all the copyrights on this technical manual．
Reprinting the parts or all of this technical manual is not allowed without permission．
FOR YOUR SAFETY!
If you operate the sewing machine first time，please make sure to read the following instructions for your
safety and proper operation．
In this technical manual，the notice CAUTION is mentioned at some paragraph to attract your attention for
the safety．Please keep it in mind whenever you work with the sewing machine．
CAUTIONis used as the notice to warn a possible danger to cause a wound
Explanationsforthewarningsigns
NO Warning sign Meanings of warning sign
1
2
3
Caution for a wound on the fingers：
Warning to a possible danger to cause a
wound on the fingers under the specified
operation．
Caution for the fingers：
Warning to a possible danger to be caught
the fingers in the machine under the
specified operation．
Caution for sewing machine operation:
Warning to operate the sewing machine
without safety guards and to prohibit
doing any operation except sewing while
the power is turned ON．

ENVIRONMENT STANDARD
1. Temperature and humidity
During operating：
The atmosphere temperature should not exceeded more 350℃(95°F) or less 5°C(41°F)．
During transportation：
The atmosphere temperature should not exceeded more 55°C(131°F) or less -10°C(18°F).
The relative humidity in the atmosphere should not exceeded more 85％or less 45％．
2. Atmosphere for the machine operation
In the atmosphere filled with dust or corrosive gas．
In the atmosphere filled with flammable or explosive gas．
3. Power source voltage
In the place where the power fluctuation exceeds more or less 10％of the fixed power voltage．
In the place where the power source cannot supply enough voltage to keep the motor running．
Pressure shall not be less than 0.6MPa.
4. Noise
In the place near a high frequency transmitter or a high frequency welder．
In the place filled with strong electromagnetic radiation or magnetic field．
Caution
★ For avoiding the sewing machine from the troubles，please do not operate the sewing
machine under the following conditions．

----- CONTENTS -----
1STRUCTURE OF THE SEWING MACHINE ..........................................................................................1
2SPECI FICATION.......................................................................................................................................2
3INSTALLATION.........................................................................................................................................3
3-1Installation of the control box......................................................................................................................3
3-2Installation of the power switch...................................................................................................................3
3-3Connection of the foot switch......................................................................................................................4
3-4Installation of the oil pan.............................................................................................................................4
3-5Installation of the sewing machine head......................................................................................................4
3-6Installation of the spindle motor..................................................................................................................5
3-7Connection of the operation panel...............................................................................................................5
3-8Connection of the electric cables.................................................................................................................6
3-9Installation of the thread stand.....................................................................................................................8
4LUBRICATION ..........................................................................................................................................8
4-1Filling the oil tank........................................................................................................................................8
4-2Oiling...........................................................................................................................................................8
5PROPER OPERATION...............................................................................................................................9
5-1Installation of the needle..............................................................................................................................9
5-2Threading the upper thread..........................................................................................................................9
5-3Winding the bobbin thread ........................................................................................................................10
5-4Settling the bobbin.....................................................................................................................................10
5-5Setting the bobbin case..............................................................................................................................11
6PROPER SEWING ...................................................................................................................................11
6-1Operation of the halt switch.......................................................................................................................11
6-2The sewing operation.................................................................................................................................12
6-3Adjustment of the thread tension...............................................................................................................13
7STANDARDADJUSTMENT...................................................................................................................14
7-1Adjustment of the needle bar position.......................................................................................................14
7-2Adjustment of the position between the needle and the shuttle hook........................................................14
7-3Adjustment of the clearance between the shuttle hook and the needle .....................................................15
7-4Adjustment of the clearance between the driver and the needle................................................................15
7-5Adjustment of the thread guide..................................................................................................................16
7-6Adjustment of the bobbin winder..............................................................................................................17
7-7Adjustment of the work holder..................................................................................................................17

7-8Adjustment of the trimmer cam follower ..................................................................................................18
7-9Adjustment of the position for the movable knife point............................................................................19
7-10Adjustment of the fixed knife position......................................................................................................19
7-11Adjustment of the thread take up spring swing stroke...............................................................................20
7-12Adjustment of the thread take up spring tension .......................................................................................20
7-13Adjustment of the thread tail after the trimming .......................................................................................20
7-14Cancellation of the trimming function.......................................................................................................20
7-15Adjustment of the upper thread tension release.........................................................................................21
7-16Adjustment of the mechanical home position ...........................................................................................21
7-17Adjustment of the X-Y table contact pressure............................................................................................22
7-18Adjustment of the X –Y t stepping motor position ....................................................................................23
8MAINTENANCE......................................................................................................................................24
8-1Cleaning.....................................................................................................................................................24
8-2Disposing of oil waste ...............................................................................................................................24
9BAD SEWING CONDITION＆ITS CAUSE AND REMEDY...............................................................25

1
1STRUCTURE OF THE SEWING MACHINE
②②
HLK-03 electronic bar tack machine is constructed with the following main parts
○
1 Sewing machine head ②Thread stand ③Operation Panel ④Control Unit
⑤Halt switch ⑥Work holder foot switch ⑦Wooden Table ⑧Steel stand
①
②
③
④
⑤
⑥
⑦
⑧

2
2SPECI FICATION
Sewing area：X-Direction(left／right) 30mm
Y-Direction(forward／backward) 30mm
Maximum sewing speed：2000 rpm
Sewing speed：variable from 200 to 2000 rpm
Stitch length：0.1 to 12.7mm
Stitch type：Single needle lock stitch
Needle bar stroke ：41.2 mm
Thread take up lever stroke：68mm
Class of needle：MT × 190 #21(the standard specification)
Wiper system ：Back to forward wiping system(the standard specification)
Presser foot lift：90mm max
Hook：Shuttle hook
Bobbin case：With non racing spring
Bobbin：Aluminum bobbin
Thread trimmer system: Horizontal engagement with fixed knife and movable knife
Lubrication system: Manual oiling and replenishment with the oil braids from the oil tanks
Lubrication oil：White machining oil
X—Y drive system：Stepping motor and X-Direction gear
Y-Direction gear Intermittent or continuous feeding
Machine dimension：1，200mm (W)× 740mm (L)×1，220mm (H)
main motor: 500W

3
3INSTALLATION
Caution
★ The machine should be installed by the specialists who have enough experience for the sewing machine
installations．
★ All the necessary electric wiring should be done by electric engineers who are qualified for the electric
wiring．
★ If any damage or fault is found on the machine at the installation，please do not operate until it is
repaired．
★ Please do not operate the sewing machine with excessive modifications from the standard specification.
3-1 Installation of the control box
If the control box is purchased without
assembling to the table, the control box has
to be installed underneath the table. Please
install the control box with the instruction in
the paragraph．
3-2 Installation of the power switch
If the power switch is purchased
without assembling to the table，the
power switch has to be attached with
the following procedure．
(1) Mount the power switch
○
1 with the
wood screw
○
2 underneath the table as
shown on the figure．
(2) Fix the electric cords with the staples
○
3 underneath the table．
(3) Hook up the connector
○
8ofthe
power switch
○
1 to the control box
○
7．
(4) Attach the power plug
○
5 to another
end of the power switch cord
○
4．

4
3-3 Connection of the foot switch
Connect the foot switch ○
6 to the control box ○ 7 .The foot switch is enclosed in the accessory box．
3-4 Installation of the oil pan
(1) Fix the oil pan ○ 1 at its four corners on the table top with four
3-5 Installation of the sewing machine head
Caution
★ For the safety，please make sure to
carry the sewing machine head by more
than two people．
(1) Make sure to hold the machine table
with the caster stopper.
(2) Fit the rubber cushion pads ○
3intothe
each hole ○
4 on the tabletop．The
rubber cushion pads are enclosed in the
accessory box．
(3) Put the sewing machine head on the
table top and set the each leg②to the
each rubber cushion pad○
3．
(4) Attach two hinges ○
6 temporarily，make the setting screw ○ 7 fastening on the left side surface of the
machine bed ．
(5) At this time，take notice that the E-shaped snap ring on the front side hinge must be come to the backside，
and E-shaped snap ring on the backside hinge must be come to the front．
(6) These parts are all enclosed in the accessory box．
(7) Fit the screw holes ○
9 of the hinges ○ 6 to the bolt setting holes ○ 8 on the table top then，pass the bolt
○
10 through these holes and fasten the bolt ○ 10 to fix the hinges ○ 6 with the flat washers○ 11 ，the spring
washers ○
12 and the nuts ○ 13 ．
(8) Fasten firmly hexagonal socket head set screws○
7，which set the hinges○ 6 temporarily then，fix the
hinges ○
6 perfectly．
(9) Insert the headrest ○
14 into the hole ○ 15 on the tabletop．

5
3-6 Installation of the spindle motor
Reference to the controller using the instructions in section 2.2 debug mode, enter "CP-1", the screen shows "
CP-1", press key to enter the CP-1,then press P1 and P2 at the same time to adjust the parameters of
the spindle motor ,Which is in number 6 point test content.
(1) Fix the spindle motor to the machine, make sure that he needle bar in the highest position and then wheel
spindle motor rotation angle to 0, tighten the screw coupling.
(2) Back to sewing mode, thread take –up lever is in the highest position, test the cutter .
3-7 Connection of the operation panel
Please connect the operation panel with the instructions of operation panel manual enclosed in the packing．

6
3-8 Connection of the electric cables
Please make sure to ground the place where there is a mark. Failure to do so may cause
electric shock and/or malfunction.

7
(1) Connect the machine head and the control box with cables as shown on the figure.
(2) Hold the dangling cables under the table with accessory tie holders and cord ties.
(3) At this time, please check whether the cables are not pulled when tilting the sewing machine.
(4) Control box back and socket as shown on the below figure
(5) Printed circuit board wiring as shown on the below figure
Control signal
one/two (X13)
interface
Electromagnet
output (X9) interface
Pneumatic
feet solenoid
valves
interface
Upper thread tension
Electromagnet interface
The Y axis detector
interface
Stop switch interface
Trimming thread
electromagnet interface
The X axis detector
interface
Cylinder
Magnetic
switch
interface

8
3-9 Installation of the thread stand
（1）Assemble the thread stand
with the instructions enclosed
in the packing．
(2) Fit the thread stand ○
1inthe
thread stand holeg on the
tabletop．
(3) Fix the thread stand ○
1firmly
from the rear side of the
table with tightening the nut
○
4andthewashers
○
2,
○
3．
4LUBRICATION
Caution
★Please make sure to turn power switch off before oiling．
★Please make sure to put some oil before starting the operation of the brand new machine or when the
sewing machine is resumed the operation after a long interval．
NOTE : Please use high quality white machining oil．
4-1 Filling the oil tank
Pour the oil through the oil hole ○
1tothe
oil tank ○
2 on the machine arm．Move
the work holder by hand to the right end
then，pour the oil through the oil hole○
4
to the oil tank○
5 on the machine bed．
Please fill with the oil over level mark○
6
of the oil tank．
4-2 Oiling
Put some oil to red marked oil
holes(NO.○
7～○ 10 )．

9
5PROPER OPERATION
5-1 Installation of the needle
Caution
★Please make sure to turn the power switch OFF before installing or replacing the needle．
★Please pay attention for the fingers not to be wounded by the needlepoint．
(1) Loosen the needle set screw ○
1then，
Insert the new needle ○
2 until the needle
head is reached the end of the hole of the
needle bar○
3．
(2) Fasten the setting screw○
1 with facing
the needle groove○
4 to the front．
5-2 Threading the upper thread
★Please make sure to turn the power switch off before threading the upper thread．
★Please thread the upper thread with referring to the below figures．

10
5-3 Winding the bobbin thread
★Please make sure to pull the upper thread out of the needle before winding the bobbin thread．
(1) Pass through the thread from the thread
stand○
4 as shown on the right figure .
then，wind the thread to the empty bobbin
○
5 in the arrow mark “a” direction couple
times and insert the bobbin○
5intothe
bobbin winder○
6．
(2) Push the adjust lever○
7 in the arrow mark
“b” direction．
※Caution: Bobbin winder does not work immediately after Turning ON the power. Perform the bobbin
winding after setting pattern NO. or the like once, pressing the key, and making the Sewing
LED light up.
(1) Press key to make the Sewing LED go off.
(2) Select the bobbin winder with key.
(3) Press key. The work clamp feet ⑨come down and the Sewing LED lights up.
(4) When the pedal ⑧is depressed, the sewing machine rotates.
(5) When the pedal ⑧is depressed again, or key or key is pressed, the sewing machine stops.
(6) When key is pressed, the Sewing LED goes off, the work clamp feet go up and key become
effective.
5-4 Settling the bobbin
(1) Set the bobbin○
2 into the bobbin case○ 1．
(2) Pull the bobbin thread○
3 into the slit○ 4 and pass the
thread through the thread hole○
5．
(3) At this time，pull the bobbin thread○
3then，check with
the bobbin○
2 if it is rotaled to the arrow direction．if it is
not，set the bobbin○
2 into the bobbin case○ 1 over again
to get the proper rotation.

11
5-5 Setting the bobbin case
(1) Set the needle bar to its highest position then，open the cylinder cover○
1．
(2) Open the bobbin case latch lever○
2 fully then，fit it securely in the inner hook○ 3．
[NOTE]Please pull the bobbin thread about 2.5cm out of the thread hole of the bobbin case．
6PROPER SEWING
6-1 Operation of the halt switch
If an incident such as a thread breakage，needle breakage and any other incidents are happened during the
sewing operation，please hit immediately the halt switch．The sewing machine running is stopped instantly．
Caution
★ Before start the sewing operation，please make sure the location of the halt switch and keep it in mind the
function and how to use it．
★ Please keep away the hands and the face from the needle during the sewing operation.
(1) Press the HALT switch○
1，All operations
will stop，and the sewing machine will stop
at the needle UP state without trimming the
thread．
(2) Remove the cause of the abnormality．
(3) To continue sewing，turn the HALT
witch to the right．The switch will be
unlocked．
(4) There are two operations after stop as below.
Press key to perform thread trimming,

12
performpositionwith or key, and re-start by means of the start switch.
Press key to perform thread trimming, and press again key to return to the origin.
※ Note: When sewing machine stops by pressing key, if you press key again, the machine
will perform trimming.
6-2 The sewing operation
Caution
★ It is very dangerous to operate the sewing machine without the safety guards(Eye guard：belt cover，Link
cover，Finger guard etc．)．
★ Please make sure to always operate the sewing machine with the safety guards．
★ Please do not put unnecessary articles except for the sewing operation on the tabletop．
★ Please keep the hands and the face away from the needle．
⑴Set a work piece on the work clamp foot section.
⑵Depress the pedal switch to the first step, and the work clamp feet will come down. If you detach your
foot form the pedal switch, the work clamp feet will go up.
⑶Depress the pedal switch to the second step after descending the work clamp feet at the first step, and the
sewing machine will start sewing.
⑷After the sewing machine completes sewing, the work clamp feet will go up, and return to the sewing
start position.
Note1: Depress the pedal switch to the first step and press or key to change the sewing
position where you need. After you confirm the position, you could depress the pedal to the second
step to start your sewing.
Note2: Please do NOT use the method in Note 1 to check the contour of a sewing pattern, in case accidents
caused by the sudden start of the sewing machine when you depress the pedal to the second step by
mistake.

13
6-3 Adjustment of the thread tension
The thread tension between the upper and bosom thread should be balanced in the best condition．
When the upper thread tension is well balanced with the bobbin thread tension，both threads are interlocked
along the centerline of fabric layers as shown on the below figures．
NOTE Normally weaker bobbin thread tension brings better sewing quality．
So it is prefer to set bobbin thread tension first and then set upper thread tension．
(1) Bobbin thread tension
Adjust the bobbin thread tension with the thread tension adjusting screw ○
2 on the bobbin case○ 1．The
thread tension becomes loose if turn the thread tension adjusting screw ○
2 to the counter clockwise，and the
thread tension becomes tight if turn it to the clockwise．
(2) Upper thread tension
Adjust the upper thread tension based on the bobbin thread tension．For this adjustment，turn the thread
tension adjusting nut○
3．The upper tread tension becomes tight if turn the thread tension adjusting nut ○ 3to
the clockwise，and the upper thread tension becomes loose if turns it to the counter clock wise．

14
7STANDARDADJUSTMENT
Caution
★Please make sure to turn the power switch OFF before adjust the sewing machine．
★If the adjustment is required under the power switch is ON，keep the start foot switch away from the foot．
★Be careful not to be wounded by the needle or the inner hook point．
★Please make sure to put the safety guards(Eye guard，Belt guard，Link cover and finger guard etc．)back on
the original location after the sewing machine adjustment．
7-1 Adjustment of the needle bar position
(1) Turn the power switch OFF．
(2) Turn the sewing machine
pulley by hand then，stop the
needle bar
○
1 at the lowest
position．
(3) Remove the rubber plug
○
2
from the face plate then，
loosen the needle bar holder
setscrew
○
3．
(4) Move the needle bar○1 to the position where the needle bar timing mark A is matched to the needle bar
bushing bottom line
○
4then，tighten the needle bar holder setscrew
○
3．
NOTE：If the needle class is DP×17，match the needle bar timing mark A to the needle bar bushing bottom
line
○
4．
7-2 Adjustment of the position between the
7-3 needle and the shuttle hook
(1) Turn the power switch OFF．
(2) Turn the sewing machine pulley by
hand then，move up the needle bar
○
1
from the lowest position and stop it at
the position
○
2 where the needle bar
timing mark C is matched to the needle
bar bushing bottom line．
NOTE：If the needle class is DP×17，
match the needle bar timing mark C to
the needle bar bushing bottom line
○
2．
(3) Open the cylinder cover
○
3．
(4) Remove the bobbin case
○
4．

15
(5) Turn the hook retainer lever○ 5then，remove the hook retainer○ 6．
(6) Loosen the driver setscrew○
9then，move the driver○ 10 and adjust the shuttle hook point○ 7 to be
matched with the center line○
8 of the needle．
(7) After the adjustment，tighten the driver setscrew○
9 and put the bobbin case○ 4，the hook retainer○ 6 and
the hook retainer lever○
5 back to the original location then close the cylinder cover○ 3.
7-4 Adjustment of the clearance between the shuttle hook and the needle
(1) Please take the same procedures as above paragraph 7-2．from(1) to(5)．
(2) Loosen the outer hook setscrew○
3 and turn the eccentric pin○ 4 so that the clearance between the shuttle
hook point and the needle becomes 0.05～0.1 mm．
(3) After the adjustment，securely tighten the outer hook setscrew○
3 and put the hook retainer and the
bobbin case back to the original location then，close the cylinder cover ○
5．
7-5 Adjustment of the clearance between the driver and the needle
(1) Please take the same procedures as above paragraph 7-2．from(1)to(5)．
(2) Please make sure the clearance between the shuttle hook point and the needle has been adjusted 0.05～
0.1 mm at above procedure 7-3 Adjustment of the clearance between the shuttle hook and the needle．
(3) Loosen the driver setscrew○
1 and turn the eccentric pin○ 2 so that the clearance between the driver○ 3
and the needle○
4 can become 0．
(4) After the adjustment，securely tighten the driver setscrew○
1 and put the hook retainer and the bobbin
case back to the original location then，close the cylinder cover○
5．