Willcox & Gibbs W562 User manual

INSTRUCTIONS
Cat. No. 9A2030 A March, 1984
W562>W542
FLATBED INTERLOCK STITCH MACHINES
First edition; issued in March, 1984
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INTRODUCTION
FOR SAFETY
This booklet contains some notes on the
operation and maintenance of the W500, which
should be useful to you and should help you to
become familiar with the machine and to
derive the best use from it.
(1) Make sure Belt Cover is properly fitted.
(2) Take care when you connect Power Cord to
Machine Motor as well as when you check
the machine before switching on.
(3) Turn off Motor Switch whenever you leave
the work table.
(4) Turn off Motor Switch in the event of
power failure.
(5) Make sure Motor has completely stopped
when you clean or inspect the machine.
(6) Be sure to turn off the power and make
sure Motor has completely stopped when
you thread the machine or replace the
needles.
DAILY MAINTENANCE
PRECAUTIONS
Before morning start
(1) Check each Needle is not damaged or bent.
(2) Check all Needles are correctly set.
(3) Check threading is correct.
(4) Check about 30mm of thread chain remains
behind Presser Foot.
(5) Check the oil jets in Oil Sight Window are
normal. Check oil is maintained at the
specified level and the hand-oiled parts are
lubricated enough.
After close of work
(1) Remove dust and lint deposits on the
machine.
(2) If any trouble or disorder is found, report
it to the plant mechanic for adjustment or
repair.
(3) Be sure to place Dust Cover over the
machine.
(1) Do not run the machine at more than 4,500
s.p.m. for the first 4 weeks.
(2) Before starting machine for the first time,
or if the machine is idle for more than a
couple of weeks, manually lubricate the
moving parts.
(3) Always keep oil level between the two lines
on Oil Sight Gauge.
(4) Change the oil at the end of the first 4
weeks.
(5) Thread correctly as shown in Treading
Diagram on Page 7.
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TABLE OF CONTENTS Page
Pattern paper for semi-submerged installation 2
Table cut-out and installation bracket 3
Driving motor pulley and belting 3
Belt guard and belting 4
The turning direction of machine 4
Machine speed 4
Lubrication 5
Replacing oil filter 6
Silicone oil for H.R. device- 6
Needles 6
Replacing needles 6
Threading 7
Regulating thread tension 8
Adjusting needle thread takeup 8
Adjusting spreader thread takeup 8
Adjusting needle thread guard 9
Adjusting thread guide 9
Adjusting needle guard (front) 9
Adjusting looper thread takeup 10
Setting looper thread guard 10
Setting thread guides 10
Presser foot pressure 11
Stitch length adjustment 11
Diff. feed ratio adjustment 11
Adjusting needle and looper 12
Needle height setting 12
Looper setting 13
Adjusting needle guard 14
Adjusting feed height 14
Adjusting feed tilt , 14
Setting position of spreader 15
Adjusting spreader stroke 15
Setting position of spreader thread guide 15
Setting thread guide 15
Adjusting foot lift 16
Adjusting spreader timing 16
Synchronizing needle bar and looper 17
Adjusting the timing between needle and looper back and forth movement ----n
Adjusting looper avoiding motion 17
Under fabric trimmer (FT140) 18—19
Metering device (MD230) 20—22
Lace guide (LG210) 22
Setting tape binder 23
Changing the maximum feed ratio 23
Replacing timing belt 24—25
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Rg.1
r-Note:-
• For a machine equipped with the under fabric trimmer (the FT device), cut the portion
• For a machine equipped with the needle positioner, cut the portion d).
-2-
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TABLE CUT-OUT AND INSTALLATION BRACKET
The semi-submerged installation is standard
for this machine.
Cut out the table and install the machine in
the following manner,
(1) Refer to Fig.l and cut out the table as
specified.
(2) Refer to Fig.2 and set O ^ ® in sequence.
If the machine is equipped with the under
fabric trimmer, refer to Fig,3 and set —
® in sequence.
r— Note:
• Use a table of thickness 50mm.
• Remove Washers o if the table is 50mm.
• Use Washers O if the table is 47mm or less.
DRiyiNG MOTOR PULLEY AND BELTING
The machine should use a motor and belt of
the following specifications:
(1) Motor: Clutch motor, 3 phase, 2 pole, 400
watts.
(2) Belt: V belt. Type M
(3) Motor pulley: Select an appropriate pulley
referring to Table 1.
Table 1
Machine speed
(s.p.m.)
Motor pulley outer diameter (mm)
60 Hz
50Hz
6,500
1 1 0
13 5
6,000
1 0 5
12 5
5,500
9 5
1 1 5
5,000
8 5
10 5
4,500
8 0
9 5
4,000
7 0 8 5
Fig.2
9
C£>
3 D
Fig.3
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BELT GUARD AND BELTING
(1) For safety, be sure to fit Belt Guard O with
Screws 0 on machine.
(2) Adjust the tension of the belt so that it can
be 2cm bent inward when you press the
middle of it.
Adjust the height of the motor to do this.
THE TURNING DIRECTION OF MACHINE
The turning direction of Machine Pulley is
clockwise, seeing the machine from its right
side.
Fig.5
MACHINE SPEED
MAXIMUM SPEED
Table 2
Make sure your machine type number with
Type Plate O and run it not exceeding the
maximum speed as listed in Table 2.
^ Note:
The maximum speed may have to be decreased
depending on sewing conditions such as fabric,
operation, needle size, thread, stitch length,
etc.
Select a correct motor pulley size from
Table 1 suitable to your operation.
MACHINE
Number of needles
MAXIMUM SPEED
(S.P.M.)
2-needle 3-needle
W562-01
O O 6,000
W542-01
O 6,500
o 6,000
W562-02
oo
6,000
W542-02
o
6,500
o 6,000
W562-03
o
o 6,000
W542-03
o
6,500
o 6,000
W562-05
o
o 5,500
W542-05
o
o 5,500
W562-06
o
o 6,000
W542-06
o
6,5 0 0
o 6,0 0 0
W562-07
o
o 5,0 0 0
W542-07
o
o 5,0 0 0
W562-21
o
o 5,0 0 0
Note: If the machine is equipped with the metering device,
the maximum -speed is 5,000 s.p.m.
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LUBRICATION
The oil was drained from the machine when
shipped. So, fill the machine with oil before
starting it for the first time.
1. Lubricating Oil
Use Mobil Velocite oil No. 10 (ISO VG22) or
equivalent.
2. To fill oil
Take out Screw O and pour fresh oil until the
oil level reaches the upper line 'H' of Oil Level
Sight Window ©. Replace Screw O.
3. Oil level
Always keep enough oil in the machine so that
the oil level is between two lines H and L of
Window ©.
4. Manual oiling
Before starting machine for the first time, or
if the machine is idle for more than a couple
of weeks, manually lubricate Needle Bar ©.
5. Oil circulation check
Be sure to check that oil is splashing inside
Window o.
(— Note:
If oil does not splash inside Window 0>
check Oil Filter ®.
6. Oil Change
Change oil after the first I month in operation.
After that, change oil every 6 months.
- Note:
Be sure to change oil because dirty oil can
cause excess wear on moving parts and
shorten the life time of the machine.
7. To drain oil
Take out Screw 0 and drain oil from here.
8. Oil Filter
If Oil Filter 0 is clogged, nomal lubrication
cannot be kept. Check and clean 0 every 6
months at the time of the regular oil change.
^ Note:
If oil jet in Window O is abnormally
restricted or weak, or oil contains bubbles,
check and clean Oil Filter 0 or if necessary,
replace it with new Oil Filter.
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REPLACING OIL FILTER
Refer to Fig. 11 and disassemble O O in
sequence.
Clean Oil Filter O or if necessary, replace it
with a new one.
SILICONE OIL FOR H.R. DEVICE
Keep Reservoirs 0 and 0 with factory supplied
silicone oil or equivalent.
Never use this oil to lubricate any machine
parts.
NEEDLES
The standard needle is as shown in Table 3.
REPLACING NEEDLES
Loosen. Screw O and replace needles.
Insert a new needle into the needle hole as far
as it will go, making sure the long groove on
the needle is facing you.
— Note:
When loosening or tightening Screw ©,
insert the tip of the alien key fully into the
hexagonal hole of Screw 0.
NEEDLE SYSTEM AND SIZE
Table 3
NEEDLE SYSTEM
NEEDLE SIZE
2-needle
3-needle
Schmetz UY128GAS
#70
#75
Organ UY128GAS
# 1 0
# 1 1
Please note that the needle size varies depending on the
number of needles in the machine.
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THREADING
Thread your machine correctly. Incorrect
threading may cause thread breakage, skip
stitches, or uneven stitch formation.
Rg.15
I
for stretchy ^
threads. *
•for fine stitch length
and narrow seam
width only.
for coarse stitch
length and
wide seam width only.
for stretchy
threads.
(DWhen threading, push
Lever o and Bracket
O will come out.
©After finishing threading,
push Bracket O into its
original position.
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REGULATING THREAD TENSION
Changes of threads, seam width, stitch length,
etc. require re-adjustment of thread tension.
Adjust individual thread tension as follows:
To increase tension:
Turn Nut O clockwise.
To decrease tension:
Turn Nut O counter-clockwise.
ADJUSTING NEEDLE THREAD TAKEUP
In the standard setting, the top edge of Bracket
© should be horizontal when the needle bar is
in the lowest position.
To adjust, loosen Screw ©.
The distance between the line (a) of Bracket ©
and the line (b) of the needle thread takeup
should be 87mm. To adjust loosen Screws ©.
f— Note:
• To tighten the needle thread, move Needle
Thread Takeup © in the (+) direction.
To loosen the needle thread, move © in
the (—) direction.
• Take care not to move Spreader Thread
Takeup © from its original position.
ADJUSTING SPREADER THREAD TAKEUP
The eye (A) of Thread Guide © should come
to the comer of Spreader Thread Takeup ©
when Spreader Thread Takeup © is in its
highest position.
To adjust, loosen Screws © and ©, and move
Thread Guide © up or down.
Fig.l7
—rr?—N /Ctr
I
T
87mm
H
(a)
-8-
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ADJUSTING NEEDLE THREAD GUARD
Set Needle Thread Guard
its elongated hole.
To adjust, loosen Screw
at the center of
ADJUSTING THREAD GUIDE
The standard position of Thread Guide ® is
as shown in Table 4.
To adjust, loosen Screw ® and move Thread
Guide ® up or down.
Note:
To tighten the thread, raise Thread Guide ®.
To loosen the thread, lower ®.
Adjust according to the type of thread used.
Lower Thread Guide ® when weak synthetic
threads are used.
ADJUSTING NEEDLE GUARD (FRONT)
As the looper passes behind the needles. Needle
Guard (Front) ® passes in front of the needles.
Set Needle Guard (Front) (D as close as possible
to the needle but only one piece of thread passes
through the gap (a) smoothly.
To adjust, loosen Screw ® and move Needle
Guard (Front) ^ back and forth.
SETTING POSITIONS OF THREAD GUIDE
Table 4
Needle
thread
Polyester
spun
Polyester
spun
Wooly
(H type)
Looper
thread
Polyester
spun
Wooly
(G type)
Wooly
(G type)
Position
of ®
Lowest
Lowest
Center
Flg.21
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ADJUSTING LOOPER THREAD TAKEUP
Looper Thread Takeup O should release the
looper thread at the point (a) when the left
needle point is in the following position.
1)2/3 down the looper for 2-needle machines.
Fig. 23.
2) level with the looper's lower edge for 3-needle
machines. Fig. 24.
To adjust, loosen Screws Q and turn Looper
Thread Takeup O.
SETTING LOOPER THREAD GUARD
Set the distance between Bracket and
Looper Thread Guard O to:
5.0—6.0mm for 2-needle machines.
6.0—7.0mm for 3-needle machines.
To adjust, loosen Screw ©.
SETTING THREAD GUIDES ® and Q
Align the eyes of Thread Guides 0 and O with
the aligning mark on Bracket 0.
To adjust, loosen Screws 0 and 0.
—Note: 1
When the looper is at its left dead point, the
looper thread between Guides 0 and 0
should be lightly tensioned. Adjust this
according to threads, stitch length and needle
gauge.
To increase the amount of thread in the
seam, move 0 and 0 down.
To decrease the amount of thread in the
seam, move 0 and 0 up.
3-needle 6.0—7.0mm
2-needle
Fig.23
3-needle
Flg.24
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PRESSER FOOT PRESSURE
Presser foot pressure should be as light as
possible, while still sufficient to feed fabric
and obtain proper stitch formation.
Loosen Nut ® and turn Screw and adjust.
STITCH LENGTH ADJUSTMENT
While pressing Push Button turn Handwheel
® until Button drops in.
Turn ® further for a desired stitch length.
Release ®.
• For a longer stitch length, turn ® in the (+)
direction.
• For a shorter stitch length, turn ® in the (—)
direction.
— Note:
The figures on Handwheel ® show
approximate stitch length.
DIFF. FEED RATIO ADJUSTMENT
The diff. feed ratio is from 1:0.7 to 1:1.3
Loosen Nut move Lever ® up or down to
change the diff. feed ratio.
To stretch the fabric, move Lever ® upward.
To gather the fabric, move Lever iB downward.
r— Note:
Fig. 30 shows approximate diff. feed ratio by
setting Lever
• The diff. feed ratio is 1:0.7 to 1:1 for W562-05'
W542-05.
^ rVfAA'
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ADJUSTING NEEDLE AND LOOPER
When the looper point is behind the left needle
centerline, it should be 1.2—1.5mm above the
top of the left needle eye, and the clearance
from the needle should be 0.1—0.2mm.
When the left needle comes down and its point
is flush with the top of the looper blade, the
distance between the looper eye center and the
left needle centerline should be 5.0—6.0mm.
Adjust in the following manner.
NEEDLE HEIGHT SETTING
The standard setting is as shown in Table 5.
The needle height is the distance (a) between
the left needle point and the needle plate
surface when the needle bar is in the highest
position.
Raise the needle bar to the highest position
and adjust the height as shown in Table 5.
To adjust, remove Cap Screw O, loosen Screw
0, and move the needle bar up or down.
—Note:
• After this adjustment, make sure that each
needle passes through the center of the needle
hole in the needle plate and that the gap (b)
is even. Fig. 36.
• When the needle bar is in its highest position,
the mark ® on the handwheel should meet
the mark (S).
1.2~ 1.5mm
Rg.31
5.0—6.0mm
Flg.32
Flg.33
(a)
NEEDLE HEIGHT
Table 5
2-needle
Needle
space
2.4mm
3.2mm
4.0mm
4.8mm
5.6mm
6.4mm
Needle height
(a)
10.2—10.7mm
9.8—10.3mm
9.3— 9.8mm
8.9— 9.4mm
8.5— 9.0mm
8.1— 8.6mm 6.4mm
3-needle
Needle
space
4.8mm
5.6mm
Needle height
(a)
8.9—9.4mm
8.5—9.0mm
8.1—8.6mm
Flg.35
(a)
/'■'i • •/.'
Flg.36
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LOOPER SETTING
The standard setting is as shown in Table 6.
Make sure that the setting is correct for your
machine.
The distance (a) is from the right needle
centerline to the looper point when the looper
is at the right dead point. Set the distance (a)
in the following steps.
[IISETTING LOOPER
Refer to Fig. 38 and set the looper.
mADJUSTING DISTANCE (a)
Set the distance (a) correctly. Table 6.
To adjust, loosen Screw O and move Looper
Holder 0 right or left.
IHGLEARANCE BETWEEN NEEDLE AND
LOOPER POINT
Set the clearance between the left needle
and the looper point to 0.1—0.2mm when the
looper point is behind the left needle
centerline.
To adjust, loosen Screw O and turn Screw 0.
• In the case of 3-needle machines, when the
looper point is behind the middle needle
centerline, the clearance should be
0—0.5mm.
25.0mm
0.9mm
R9.38
DISTANCE BETWEEN NEEDLE AND LOOPER Table 6
2-needle 3-needle
Needle
space
Distance
(a)
Needle
space
Distance
(a)
2.4mm 4.6—4.9mm
3.2mm 4.2—4.5mm
4.0mm 3.8—4.1mm
4.8mm 3.4—3.7mm 4.8mm 3.4—3.7mm
5.6mm 3.0—3.3mm 5.6mm 3.0—3.3mm
6.4mm 2.6—2.9mm 6.4mm 2.6—2.9mm
Fig.39
i-H(a)
/ Fig.40
1.2—1.5mm
"■Q
Fig.41
5.0~6.0mm
Fig.42
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ADJUSTING NEEDLE GUARD
Needle Guard O should work so that the
clearance between the right needle and the
looper point is 0—0.05mm when the looper
point is behind the right needle centerline. Also
that the clearance between the middle needle
and the looper point is 0 — 0.05mm when the
looper point is behind the middle needle
centerline.
1. Adjust so that the line (A) of Needle Guard
O is 1/3 below the top of the right needle eye
when the needle is in the lowest position.
Fig. 43.
To adjust, loosen Screw O and move Needle
Guard O up or down.
2, To obtain the above clearances 0 —0.05mm,
loosen Screw © and move Needle Guard O
back and forth.
ADJUSTING FEED HEIGHT
When the main feed dog is in the highest
position, set the height to 0.8 — 1.0mm.
Adjust the diff. feed dog so that the point B is
on the same level as the main feed dog point C.
To adjust, loosen Screws O and ©, and move
the feed dog up or down.
ADJUSTING FEED TILT
The teeth of the feed dogs should be level with
the needle plate surface when they first appear
above the needle plate surface.
To adjust;
1. Remove three Screws 0 and Cover 0.
2. Remove Plug 0 and loosen Screw 0.
3. Open Side Cover 0 and remove Screw 0.
4. To adjust the feed tilt, insert a screwdriver
into the adjusting hole and turn Screw ®.
[— Note:
• The feed tilt is altered by turning Screw 0.
Set Screw 0 to the correct position and
tighten Screw 0.
• Make sure that the shaft does not slide out
when Screw 0 is turned.
• Remember to adjust the feed height after
the feed tilt adjustment.
0.1 ~0.2mm
Rg.46
0.8—1.0mm © (p)
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SETTING POSITION OF SPREADER
HEIGHT: The height of the spreader from the
needle plate surface should be 9.2 — 9.7mm.
SIDEWISE POSITION: The hooking point
should pass the point (A) approximately 0.5mm
in front of the left needle. When the spreader
reaches its left dead point, the hooking point
should be at the point (B) 3.5 — 4.0mm from the
left needle.
To adjust:
1. Lightly loosen Screws 9 and #. While
turning Lever move Spreader ® back and
forth to set the sidewise position. Tighten
Screw 9.
i—Note:
After making the above adjustments, turn
the handwheel and check points (A) and (B)
for Spreader 9.
2. Move Spreader # up or down, and set its
height to 9.2 — 9.7mm. Tighten Screw
ADJUSTING SPREADER STROKE
The stroke of Spreader is 16.0mm.
1. Remove the arm cover and Screws ®, and
shift Cover ®.
2. Loosen Nut © and move Rod ® up or down.
• To decrease the stroke, move Rod ® up.
To increse the stroke, move Rod ® down.
SETTING POSITION OF SPREADER THREAD GUIDE
Set the part (a) of Thread Guide 0 just below
the eye of Guide ® when the needle bar is in
the lowest position. Also, set the clearance
between Thread Guide ® and Spreader ® to
0.5mm.
SETTING THREAD GUIDE
When the needle bar is in the lowest position,
set the clearance between Spreader Thread
Guide ® and Thread Guide ® to 1.0mm.
The eye of Thread Guide ® should face
forwards.
1.0mm
0.5mm
9.2~9.7mm
Fig.49
Needle plate
top surface
0.5mm
3.5~4.0mm
16.0mm
-15-
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ADJUSTING FOOT UFT
The standard setting is as shown in Table 7.
The foot lift is the distance (a) between the
presser foot and the needle plate when the
presser foot is raised.
To adjust:
1. Turn the hand wheel and lower the feed dogs
to their lowest position.
2. Loosen Nut © and tighten Screw ®.
3. Lower Lever o and raise Presser Foot O to
the correct height (a) for your machine.
4. In the above condition, adjust Screw © so
that its head touches Lever O.
Lock this position with Nut ©.
Table 7
Machine type
Presser foot lift
2-needle 3-needle
W562-01
7 . 0 mm
5 . 0 mm
W542-01
7 . 0 mm
7 . 0 mm
W562-02
7 . 0 mm
5 . 0 mm
W542-02
7 . 0 mm
7 . 0 mm
W562-03
7 . 0 mm 5 . 0 mm
W542-03
7 . 0 mm
7 . 0 mm
W562-05
6 . 0 mm 5 . 0 mm
W542-05
7 . 0 mm 7 . 0 mm
W562-06
6 . 0 mm
5 . 0 mm
W542-06
7 . 0 mm 7 . 0 mm
W562-07
6 . 0 mm
5 . 0 mm
W542-07
7 . 0 mm
7 . 0 mm
ADJUSTING SPREADER TIMING
To adjust the timing of Spreader against
the needle bar:
1. Remove the arm cover. Remove Screws ©
and move Oil Guard © to one side.
2. Loosen two Screws ©. Position the aligning
mark © of the upper shaft with the mark ®
of the eccentric.
Tighten Screw ©.
-16-^
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SYNCHRONIZING NEEDLE BAR AND LOOPER
The looper should be at the right dead point
when the needle bar is in the lowest position.
The looper should begin to move as the needle
bar begins to rise. The looper should pass
behind, and then return in front of the needles
at exactly the same level.
To adjust:
1. Remove the arm cover.
2. Loosen 4 Screws ®, turn Handwheel ® and
shift the position of Upper Belt Gear
• To advance the looper timing against the
needle, shift the position in the (+) direction.
• To retard the looper timing against the
needle, shift the position in the (—) direction.
- Note:
The looper holder is at the right dead point
when the needle bar is in its lowest position.
Synchronization between the needle bar and
the looper may change when the looper
avoiding motion is adjusted.
In this case, adjust as above.
ADJUSTING THE TIMING BETWEEN NEEDLE
AND LOOPERS BACK AND FORTH MOVEMENT
To adjust this timing, loosen Screw O and align
the mark © on Eccentric ® with the mark ©
on the crankshaft.
ADJUSTING LOOPER AVOIDING MOTION
The looper goes behind the needles to the left
dead point and then returns in front of the
needles to the right. Adjust the looper avoiding
motion according to the needle size.
1. Loosen Nut ® and turn Adjusting Screw ®.
To increase the looper avoiding motion, turn
Adjusting Screw ® counter-clockwise. To
decrease it, turn ® clockwise.
—Note:
•After the above adjustment, check the
synchronization between the needle bar and
looper. If it has been changed, re-adjust.
•Please note that the looper avoiding motion
may not be necessary to be adjusted unless
otherwise an extremely different size needle
is fitted.
-17-
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UNDER FABRIC TRIMMER (Fn40)
The under fabric trimmer of the W500 is a
continuous type.
The knife movement is synchronized with the
feed dog motion.
The knives trim the excess fabric before sewing
so that together with the lace fed by the
metering device, it can be sewn neatly.
Lubrication
Before the machine is operated for the first
time or after it has been idle for a period of
time, oil Crank O.
Adjusting fabric guide
Fabric Guide O ensures a constant distance
between the fabric edge and the right needle.
To adjust, loosen Screw O and move Fabric
Guide O right or left.
Adjusting presser foot tilt
The presser foot on the W500-05 can be tilted.
Adjust this according to the elastic and fabric
to be sewn. For thick elastic, tilt the front
edge of the presser foot upwards. The elastic
can then feed smoothly under the presser foot.
To adjust, loosen Nut © and turn Screw @.
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