Titan DK 2500 User manual

TITAN DK 2500
English
OPERATOR'S MANUAL
NV. A. DE KONINCK
Avenue Sleeckx 84-86
B-1030 BRUSSELS -BELGIUM
Phone : ++32/2 216 31 40 Fax : ++32/2 242 41 89
E-mail : [email protected] Web : www.titansew.com

Chapter 1: Installation and lubrication
1. INSTALLATION ................................................................................................................................3
a. Complete machine - with motor and table.................................................................................3
b. Sewing head only .......................................................................................................................5
2. LUBRICATING THE SEWING HEAD....................................................................................................5
Chapter 2: Threading
1. TYPES OF YARNS.............................................................................................................................7
a. Needle yarn................................................................................................................................7
b. Chain yarn .................................................................................................................................7
2. THREADING ....................................................................................................................................7
a. Needle thread.............................................................................................................................7
b. Chain yarn .................................................................................................................................7
Chapter 3: Stitch formation
1. CHAIN YARN FEED ..........................................................................................................................9
2. Stitch density setting......................................................................................................................11
a. On standard equipment............................................................................................................11
b With the stitch density regulator...............................................................................................11
Chapter 4: Mechanic adjustment of the sewing head
1. TYPES OF NEEDLES .......................................................................................................................13
a. How often are the needles to be replaced?..............................................................................13
b. Needle replacement..................................................................................................................13
c Needle height adjustment ..........................................................................................................15
d. Replacing the needle bar and adjusting the needle height ......................................................15
2. UPPER LOOPER..............................................................................................................................17
a. Preparatory work.....................................................................................................................17
b. Replacing the upper looper .....................................................................................................17
c. Upper looper fine adjustment...................................................................................................17
3. THE LOWER LOOPER .....................................................................................................................19
a. Preparatory work.....................................................................................................................19
b. Replacing the lower looper......................................................................................................19
c. Adjusting the upper looper to the lower looper .......................................................................21
d. Adjusting the distance between needle and lower looper........................................................21
4. THE CUTTING MOTION...................................................................................................................23
a. Renewing the upper knife.........................................................................................................23
b. Renewing the lower knife.........................................................................................................23
c. Knife fine adjustment ...............................................................................................................23
d. Aligning the lower blade with the needle plate........................................................................23
5. THE PRESSER FOOT ................................................................................................................. 23-25
6. FEED-DOG.....................................................................................................................................26
7. CHAIN GUIDE ................................................................................................................................27
8. STITCH PLATE FINGER ...................................................................................................................27
Chapter 5: Maintenance schedule
Maintenance schedule........................................................................................................28
From the Library of Superior Sewing Machine & Supply LLC

TIT AN DK2500
YARN STAND
ADD OIL HERE
OIL LEVEL
i------------------------------.
I ·-........_
25841VSC
@a,...___
25841E
25841R
2587012P
LOOPER YARN
25882 ........._
FIG 1.1
2 5884 ........._
25882V
I
vsET 25884
I
I T 16/12/04
From the Library of Superior Sewing Machine & Supply LLC

Chapter 1: Installation and lubrication
1. Installation
a. Complete machine - with motor and table
For units, supplied complete with motor and table, use FIG 1.1+1.4
1. Mount the yarn-stand 25850/2P en screw it on the table.
2. Mount the yarn guide plate SET 25884 on the table.
3. Place the black rubber anti-vibration blocks(25840) in the aluminium holders .
4. Take the TITAN DK 2500 machine out of its box. TAKE CARE NOT TO LIFT UP
the machine by holding the UPPER PARTS. Instead, place your hands
underneath the closing plate of the machine, and lift the machine. Place the 3
little feet attached at the lower plate, precisely in the black rubber blocks.
5. Look underneath the table, and loosen the nut of the motor, with a flat key of 24.
This allows the motor to rotate upwards or downwards .
6. Push with one hand the motor upwards, and place the driving belt (attached to
the sewing machine) (M10012) around the pulley of the motor. Push the motor
down to stretch the belt slightly as seen in FIG 1.2.
FIG 1.2
7. Unscrew the cover marked “OIL” on the machine. Take the two oil bottles out of
the box and fill the machine with 1.5 L oil. Check if sufficient oil has been added
by looking at the oil-level glass. The oil level should be exactly between the two
red arrows. Close the cover again.
The electric motor is supplied, connected for use on 380V/3 PHASE supplies. For use
on 220V/3PH supplies, use the connection diagram (FIG 1.3). Connect the cores of
the mains to the receptacles of a plug designed for local operation (not included).
Verify that the direction of rotation is correct (FIG 1.1).
FIG 1.3
-----------
--------
---
--
Tightened too strongly
Well
Z Y X z y X
~ ~ f@1
bl bl bl
~
(~
~
@ @ @
w V u w V u
220 VOLT 380 VOLT
From the Library of Superior Sewing Machine & Supply LLC

TIT AN DK25OO ELECTRONIC MOTOR
ADD OIL HERE
OIL LEVEL
YARN STAND
i------------------------------.
I ·-........_
25841VSC
@a,...___
25882 ........._
2 5884 ........._
FIG 1.4
25882V I
25841E
vsET 25884
25841R
I
I T 16/12/04
2587012P
From the Library of Superior Sewing Machine & Supply LLC

b. Sewing head only
The sewing head requires a drive motor that must meet the following specifications:
motor rating¾
HP and rated load speed 2.800 rpm.
Use a pulley 80 mm in diameter to match the V belt.
Verify direction ofrotation (FIG 1.1)
Prior
to starting the sewing machine, always make sure to pour about 1,5 Iof oil into
the machine.
See previous paragraph for more information about this.
I 2. Lubricating the sewing head
Utilising splash lubrication, the sewing head is designed for optimum lubrication of all
the components concerned. To get the maximum performance, never run the
machine with oil level lower
than the minimum level line. The sight-glass allows quick
determination of
the oil level (see FIG 1.1+1.4).
ATTENTION: the machine should NEVER RUN WITHOUT OIL.
The machine will loose daily a small amount of oil. An inspection at periodical intervals
is recommended. Ifrequired, refill the oil reservoir by unscrewing the filler plug
marking OIL just above the sight-glass.
Very important: oil type SP68.
The type of oil to be used in this sewing machine should be offollowing viscosity:
SP68.
Recommended oil types: CASTROL-ALPHA SP68 or any similar oil grade.
ATTENTION: Use oflow-viscosity oils will result in poor lubrication properties and
excessive wear, which in turn will necessitate early renewal ofthe internal parts.
Conversely, use of high-viscosity oils
will lead to lines clogging, which in turn will
necessitate early renewal ofthe spare parts from lack of lubrication.
VERY IMPORTANT: OIL should be completely removed and new oil should be added
(1.5
I.) ONCE A MONTH. This is best done after a few hours of operation
Remove the plug for oil draining underneath the machine and let the oil leak in a
bucket. Replace the
plug and add new oil (1.5 I) through the plug marked OIL.
If the oil is strongly polluted, it is recommended to remove the cover underneath the
machine
and to remove all excess deposit, which has accumulated on the cover.
Change the gasket (25839J)
and close the cover. Place the machine on the table and
refill the machine with oil as described above.
From the Library of Superior Sewing Machine & Supply LLC

25900
TIT AN DK2500
THREADING DIAGRAM
DETAIL A
SCALE 2/5
25900A
25900B
SEE DETAIL A
FIG 2.1
T 07/01/2005
From the Library of Superior Sewing Machine & Supply LLC

Chapter 2: Threading
1. Types of yarns
a. Needle yarn:
Many types of yarns can be used on the machine. Good results have been obtained
with following qualities : Nylon polyamide yarn of thickness 30 or 40,
Monofil (invisible) thread of 750 denier. (0,3 mm diameter) or
cotton (for example, mercerized cotton, thickness No.18).
b. Chain yarn (or “looper yarn”):
A wide range of threads can be used with DK 2500 machines.
Good results have been obtained with following qualities:
Polypropylene and Polyamide Nylon are most frequently used in thickness ranging
from 1800 detex till 5200 detex. The threads should be very lightly twined. This
gives better results after sewing, because the thread flattens out and covers the
carpet better.
Other qualities like wool, acrylic or cotton have also been used with success.
2. Threading
Remark: always switch off the motor prior to threading the yarns!
a. Needle thread
Refer to FIG 2.1 THREADING DIAGRAM for the details.
b. Chain yarn
1. Turn the hand-wheel by hand and bring the take-up Din its topmost
position. Lead the yarn thru the tension-adjusters Aand Band by hole Cthru the
plates on both sides of the take-up D.
2. Turn the hand-wheel by hand and bring the take-up Din its bottommost
position. In this position the eye of the lower looper faces the threading tube E
3. Thoroughly clean (if necessary, using the threading needle, part 25900) the
lower looper's eye.
4. Tightly wrap the chain yarn around the point of the threading needle and push it
all the way (as far as possible) into the threading tube and through the eye of the
lower looper F.
5. Gently remove the threading needle and push some more chain yarn into the
threading tube in order to obtain a small tangle of chain yarn behind the lower
looper's eye F. REMARK: Remember : remove the THREADING NEEDLE ALWAYS.
6. Turn the flying-wheel by hand to make sure the chain yarn extends above the
needle plate.
7. Make sure the needle thread remains threaded. The sewing machine is now
ready for use.
Note: For improved covering, use two or three thinner threads in the lower
looper.
From the Library of Superior Sewing Machine & Supply LLC

TIT AN DK25OO
STITCH ADJUSTMENT LOOPER YARN
NEEDLE YARN
LOOPER YARN
CARPET
A: OK
B: NOT OK
FIG 3.1
C: NOT OK D. NOT OK
D J
C
H
FIG 3.2
FIG 3.3
FIG 3.4
IMITATION 3-THREADSTITCH
T 25/11/04
From the Library of Superior Sewing Machine & Supply LLC

Chapter 3: Stitch formation
1. Chain yarn feed
It is recommended to keep the pressure on the springs to a minimum on the thread
tensioners A, B and G(FIG 2.1).
Note:
Always make sure the chain yarn is positioned underneath the yarn drawing lever D
(or “take-up”) (see FIG. 2.1-3.2). Failure to do so, will result in improper stitch
formation. To avoid this, check if the machine has been threaded properly (see
chapter 2b).
FIG 3.1A: Correct stitch formation, the chain yarn and the needle thread have both
absolutely uniform tensions.
FIG 3.1B: Either insufficient chain yarn tension, or excessive needle thread tension
FIG 3.1C&D: Either excessive chain yarn tension, or insufficient needle thread tension
With the take-up lever Dcorrectly set, the amount of thread thus fed will assure
successful overlocking of the carpet.
In the event of insufficient thread feed (or with thicker carpets), however, undue
tension will be placed on the chain yarn along the edges of the carpets, which in turn
will pull the needle thread from the carpet backing (see figure 3.1C).
To remedy: adjust the take-up lever Dslightly in the direction of C3 (see figure 3.5).
Conversely in the event of excessive thread feed (or with thin carpets), the chain yarn
will be found to be slack around the carpet edges (see figure 3.1B).
To remedy: adjust the take-up lever Dslightly in the direction of C1 (see figure 3.5).
If the machine isn’t equipped with RFR fine adjustment gear (see figure 3.3), the
position of take-up lever Dis to be changed as follows:
Untighten the screw of the arm I(figure 3.2) and place the take-up lever Dinto the
wanted position (higher=less thread, lower=more thread) afterwards, tighten the
screw of arm I again.
RFR fine adjustment assembly: standard in the new machines (from 2004 on)
To adjust the thread feed : loosen the screw J (FIG 3.3). Push the bar (lever)
towards “+” to increase thread feed, towards “-“ to decrease thread feed.
Note: For the typical two-thread overlock stitch, insert the chain yarn in the Ceye as
illustrated in figure 3.2 and 3.3
For special stitch formation similar to a three-thread stitch (see figure 3.4), pass the
chain yarn through the H eye (see figure 3.2 and 3.3) and then adjust thread feed so
that the stitch thus formed is similar to the one shown in figure 3.4.
From the Library of Superior Sewing Machine & Supply LLC

TIT AN DK2500
STITCH ADJUSTMENT STITCH WIDTH
FIG 3.6
STITCH ADJUSTEMENT
STANDARD
FIG 3.7
STITCH ADJUSTEMENT
WITH RPR
L
K
M
T 25/11/04
From the Library of Superior Sewing Machine & Supply LLC

FIG 3.5
2. Stitch density setting (per cm)
a. On standard equipment
• Unscrew and remove the big knurled screw to allow access to nut K
(FIG 3.6).
• Turn the hand-wheel by hand to secure the needle in its bottommost position.
• Holding the hand-wheel in position with your right hand, unscrew (counter
clockwise) the nut Kby ½ a turn using a M10 hex key.
• Place the nut Keither forward or backward as appropriate. Thus you will
increase/reduce stitch density per cm (see figure 3.6).
• Retighten the nut K and replace the knurled screw on the sewing head!
b. With the stitch density regulator (RPE/DK 2500 SEE OPTIONAL ATTACHMENTS)
The RPE option as illustrated in figure 3.7 is fitted on to the left-hand side of the
sewing machine.
• Loosen both L screws.
• Turn the disc Mcounter clockwise.
• By turning the adjuster screw N clockwise,you increase stitch density.
By turning the adjuster screw Ncounter clockwise,you decrease stitch density.
• For best results, we recommend to sew first on a small piece of carpet to see if
the correct amount of stitches per cm has been obtained.
• To secure the adjuster screw Ninto position, turn disc Mclockwise until it can
not move further.
• Slightly tighten both Lbolts to lock the settings.
The RPE option is designed to guarantee optimum sewing result with any carpet
quality and/or yarn thickness.
,
I
From the Library of Superior Sewing Machine & Supply LLC

TIT AN DK2500
NEEDLE REPLACEMENT & ADJUSTMENT
X
PLACE NEEDLEBAR IN HIGHEST POSITION.
D
R
FIG 4.1
T 26/11/04
From the Library of Superior Sewing Machine & Supply LLC

Chapter 4: Mechanic adjustment of the sewing
head.
!! Remark: Always switch off the motor before adjusting whatever part of the machine !!
1. The needle
The table below is a breakdown of typical needle types.
Type: Description Suitable for:
7713/230T Standard needle Medium carpets
7713-99/230T Square pointed needle Heavy car carpets
7713-99/230TP Needle with flat holder Heavy Car carpets
7713-99/230TPC Golden needle For automatic systems DK 4600
7713-200T Medium thick needle Light carpets
7713/180T Medium thin needle Light carpets
7713/160T Thin needle Blankets
7713/130T Ultra thin needle Fabrics (butt-seamer DK 2500E
and 2510E series)
For special purposes, please contact our service department for additional information.
tel.: ++32/2-216.31.40
a. How often are the needles to be replaced?
Considering the typical up and down movement of needles on DK 2500 series sewing
machines is about 2.800 movements per minute, needles will need replacing after a
couple of days as they become blunt, thin, and the groove disappears, thus result :
false stitches.
Assuming the machine is used for one 8-hour shift, the needle will have pierced the
carpet approximately 6 million times in one week (40h). Depending on carpet quality,
we advise to replace the needle at least once a week.
b. Needle replacement
While sewing, a circle of dust will be built up around the needle holder. It is very
important to remove first any dust that may have accumulated, prior to fitting a
replacement needle! If not, dust accumulation in the needle holder may probably
modify the exact movement of the needle, which will result in false or bad stitch
formation and may drastically decrease the life time of internal parts.
From the Library of Superior Sewing Machine & Supply LLC

Needle guide.
DK 2500.
I HEAVY C ARPETSI
25559A
. !NORMAL CARPETS!
PART NR.
-25559-230
-25559-200
PART NR.
- 25559A
25559B
NEEDLE NR.
-7713/230
-7713-99/230
-
7713 / 200
NEEDLE NR.
- 7713 / 110
-7713/130
- 7713 / 160
- 7 713 / 180
-7713 / 200
From the Library of Superior Sewing Machine & Supply LLC

SET 25559A
Afstelling van de naaldgeleiding.:..
-Stukken 25559A en 25559B
worden
los op de naaldplaat
bevestigd met schroef 25559V.
-Stukken 25559A
en 25559B
maximaal
openschuiven,
- De afstelling gebeurt steeds
. met een nieuwe naald.
- We zetten de risald in haar
onderste dode punt.
- We sluiten stukken·25559A en
25559B rond de naald zodat
er geen voorwaartse of
achterwaartse speling meer is.
- We schroeven, schroef 25559V
vast.
Adjustment of the needle-g~
- Fix parts 25559A and 25559B
·mobile o~
the needle plate _.,,
with screw 25559V. ·
-Push
the parts 25559A and
25559B maximum open.
-Adjustment must always be
done with a new needle.
- Put the· needle in her lowest
death point,
- Close parts 25559A and 25559B
around the needle in such a
way that there is no more
backward
or forward play.
- Fix the screw 25559V.
Reglage du guide-aiguille.
- Pieces 25559A et 25559B sont
fixees mobile sur la plaque a
aiguille avec la vis 25559V.
-
Ouvrir lea pieces 25559A et
25559B maximum.
- L'ajustement se fait toujours
avec une nouvelle aiguille •
-
Positioner l'aiguille a son
point mort inferieur.
-Fermer les pieces 25559A et
25559B auteur de l'aiguille
si bien qu1 il n'y a plus de.
j eu en avant ou en arriere ~
- Serrer la vis 25559V,
Einstellung der nadelfuhrung.
- Teile 25559A und 25559B
milssen Mobil
auf die Nadel-·
Platte befestigt werden mit
Schraube 25559V •.
- Teile 25559A und 25559B
maximal
aufschieben.
- Die Einstellung musz immer
geschehen mit einer neue Nadel
-
Setzen Sie die Nadel in Ihre
unterste Tode Funkt.
- Schlieszen Sie Teile 25559A
und 25559B rund
die Nadel
sodasz es kein vorwarts oder
ri.i.ckwarts Spiel mehr gibt.
- Schraube 25559V fest
schrauben.
From the Library of Superior Sewing Machine & Supply LLC

TIT AN DK2500
NEEDLE REPLACEMENT & ADJUSTMENT
H
FLAT SIDE NEEDLE PARALLEL
WITH LOWER LOOPER
5
FIG 4.2
SEE DETAIL A
5
FIG 4.3
w
DETAIL A
SCALE 3/ I
LOWEST POSITION
OF NEEDLE POINT
.!!!
T 07/01/2005
From the Library of Superior Sewing Machine & Supply LLC

To replace worn out or broken needles, proceed as follows:
• Loosen the screw H(see figure 4.1) and remove the needle.
• Remove accumulated dust in the needle-holder.
• Fit in a replacement needle. Make sure to position and push the new needle
fully home into the needle-holder.
• Be sure the groove of the needle faces the front and that the flat side on the
back of the needle is mounted parallel to the flat face of the lower looper S(FIG
4.2). To check this, turn the hand-wheel by hand and have the lower looper and
the needle cross.
• Retighten the screw H.
• Check the needle position according to chapter 4.1c .
c. Needle height adjustment
With the needle having reached the top of its stroke, distance between the needle
point and the needle plate must be exactly 23 mm (see figure 4.1).
For fine adjustment of the needle height:
• Loosen the screws Hfirst while holding the needles by hand (see figure 4.1).
• Push the needle against the screw F.
• If adapting screw F, you first have to unscrew the screw G.
• By turning the screw F, the needle height will be increased or reduced
(clockwise/counter-clockwise).
• Retighten the screw G and also screw H
!! The following instructions are restricted to qualified personnel only !!
d. Replacing the needle bar and adjusting the needle height.
Replacing the needle bar
• Loosen the screws Aand remove the worn out needle bar B(figure 4.1) from
clamp C.
• Loosen the screw Xand recuperate the needle holder W.
• Fit the needle holder Winto the new needle bar and tighten screw Xto secure
the needle bar.
• Place a new needle in the needle holder W.
• Check the parallelism between the needle and the needle bar. If these 2 parts
are not parallel, it is strongly advised to replace the needle holder W
• Fit the new needle bar into the holder Cand lightly tighten the screws A.
• Turn the hand-wheel by hand to place the needle at the top of its stroke
(highest position).
• In this position, the distance between the needle point and the needle plate
(25558) must be exactly 23 mm (figure 4.1).
Adjusting the needle height
• Loosen the screws A in FIG 4.1. By doing this, the holder Cwill loose its grip
on needle bar B(figure 4.1).
• The position of the needle can be adjusted to the top dead point being 23 mm.
• Retighten the screws A.
• Verify, by turning the hand-wheel by hand, if the needle is moving up and down
right in the centre of the needle plate (Fig.4.1 Detail).
Optimum needle thread loop formation setting
To achieve optimum needle thread loop formation, make sure the position of the
needle with respect to the lower looper S, is correct.
• Turn the hand-wheel by hand and bring the needle to reach the bottom of its
stroke (lowest position)
• Turn the hand-wheel a little further (see figure 4.3) until the needle has travelled
1,2mm on the upward stroke.
• In this position, the point of the lower looper should just pass behind the needle
as seen in Fig. 4.3 + Detail A.
From the Library of Superior Sewing Machine & Supply LLC

TITAN DK25OO
UPPER LOOPER ADJUSTMENT
5mm
V
T
FIG 4.4
T 29/11/04
From the Library of Superior Sewing Machine & Supply LLC

2. Upper looper
a. Preparatory work
In order to replace the upper looper, the cover and some other parts have to be
removed. We strongly advise to proceed as follows:
• Loosen the two screws 25833V and remove the protective plate (25833).
• Release the pressure on the pressure foot.
• Loosen the two screws 25556V and remove the needle (7713/230T).
• Loosen the two screws 25558V and remove the needle plate (25558).
• Loosen the screw 25804VL and remove the threader unit (25804).
• Loosen the screw 25655V and remove the lower blade (25655).
• Loosen the screw 25744V and remove the feed dog (25744).
• Loosen the two screws 25700V and remove the upper looper (25705).
b. Replacing the upper looper
• Turn the handwheel by hand and push the lower looper to its furthermost
backward position. This action will give the operator access to the screws T
(FIG 4.4).
• Unscrew these and replace the worn out upper looper with a new one (25705).
• Retighten the screws T.
• Turn the hand-wheel by hand for the upper looper to reach its top of its stroke.
• Make sure the outer end of the upper looper extends for 5mm beyond the edge
of the needle, as illustrated in figure 4.4.
If this is not the case, adjust correct position via the screws Tas in figure 4.4.
c. Upper looper fine adjustment
Our sewing machines are factory-set to sewing medium quality carpets with medium
quality yarns.
When using thicker/finer yarns deviating from the factory-set typical yarn thickness,
we recommend that the position of the upper looper be adjusted as follows:
Loosen the T screws (figure 4.4) and turn the hand-wheel by hand for the upper
looper to reach the top of its stroke (highest position).
In the event of thick yarns, move the point of the upper looper a little to the left
(0,5mm maximum), so that the distance between the outer end of the upper looper
and the edge of the needle is 5,5mm.
In the event of fine yarns, move the outer end of the upper looper a little to the right
(0,5mm maximum), so that the distance between the outer end of the upper looper
and the edge of the needle is 4,5mm.
Note: With every change of the upper looper, check the following points while turning
the hand-wheel by hand:
When the upper looper Vand the lower looper S(figure 4.5) cross one another on the
upper looper upward stroke, the end of the upper looper Smust travel right in the
centre of the recess of the lower looper S.
On its upward stroke towards the needle, the end of the upper looper V, must not
touch the lower looper Sand needle (no contact is allowed). Should this occur
anyway, follow the steps below. After having adjusted the upper looper, put back all
parts and put back again the pressure on the pressure foot.
From the Library of Superior Sewing Machine & Supply LLC