$GMXVWPHQW - Toyota Textile Machinery

Section M.2

Disassembly/Reassembly/Adjustment

Contents

M.2.1 Main Motor Bearings, Weft-insertion-related Components,Selvage-forming-related Components,

Reed, and EDP Ceramic Piece㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀M.2-1

[1] Replacement of Main Motor Bearings㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀M.2-1

[1.1] Replacement Interval and Bearing Types㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀M.2-1

[1.2] Motor Description㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀M.2-2

[1.3] Removal of Motor㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀M.2-4

[1.4] Replacement of Bearing ㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀M.2-6

[1.5] Installation of Motor㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀M.2-7

[2] Adjustment of Separate Brake㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀M.2-8

[3] Replacement of Weft-insertion-relatedComponents ㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀M.2-9

[3.1] Air Filter㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀M.2-9

[3.2] Replacement of Electromagnetic Pin for EDP㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀M.2-12

[3.3] Replacement and Honing of Upper andLower Blades of Mechanical LH Cutter㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀M.2-19

[3.4] One-touch Elbow (Pulling Out the Air Hose)㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀M.2-21

[3.5] Valve Inspection ㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀M.2-22

[3.6] Valve Disassembly, Cleaning and Assembly Procedure ㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀M.2-22

[3.7] Procedure to Disassemble ABSSolenoid and Replace Parts㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀M.2-32

[3.8] APC: Regulator with motor (option)㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀M.2-34

[4] Replacement of Selvage-forming related Components㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀M.2-37

[4.1] Leno Bobbin Holders㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀M.2-37

[5] Cleaning of Reed㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀M.2-40

[5.1] Cleaning the Reed on the Machine ㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀M.2-40

[5.2] Cleaning the Reed Removed from theMachine, Using Ultrasonic Cleaner(before Storage)

㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀M.2-42

[6] Repairing of EDP Ceramic Piece ㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀M.2-43

[6.1] How to JudgeWhether the CeramicPiece is Reparable or Not㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀M.2-43

[6.2] How to Repair㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀M.2-44

[7] Replacing the Inverter’s Capacitorsand Cooling Fans㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀M.2-45

M.2.2 Blower Motor(for Filament or Glass Fiber) ㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀M.2-46

M.2.3 Replacement of Felt, FeltStopper, and Body Bushing(Glass Specification)㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀M.2-47

M.2.4 Replacement of Metal Parts ofCloth Roller Wheel ShaftBracket㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀M.2-49

[1] Pulling Out the Metal Parts㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀M.2-49

[2] Forcing in Metal Parts㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀M.2-49

M.2.5 Maintenance of Valve forTucker ㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀M.2-50

[1] Parts Structure㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀M.2-50

[2] Disassembly㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀M.2-51

[3] Assembly㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀M.2-52

M.2.6 Tucker Cutter Maintenance㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀㌀M.2-54

M.2.1 Main Motor Bearings, Weft-insertion-

related Components,Selvage-forming-

related Components, Reed, and EDP

Ceramic Piece

[1] Replacement of Main Motor Bearings

Before proceeding to the motor replacement work,

be sure to turn off the main power switch.

[1.1] Replacement Interval and Bearing Types

(1) Replacement interval

Replace bearings 1 and 2 approximately once

every three years (24 hours/day as operation

hours).

If the environment contains excessive dirt, dust,

or fly, or if the motor temperature is high due to

excessive tension of the V belt, then grease may

deteriorate and flow out.

Based on these conditions, make the replacement

intervals shorter.

NOTE: The special bearings are adopted for

bearing 1 and 2 of the main motor.

Ordinary bearings (prelubricated with

Arbania No.2 or its equivalent) shall not

be used since they will shorten the

bearing service life.

M.2.1 Main Motor Bearings, Weft-insertion-related Components,Selvage-forming-related Components, Reed, and EDPCeramic Piece

M.2-1

[1.2] Motor Description

(1) Without brake

1．Structure

The main motor is a shielded, outer-fan, 3-

phase, induction motor.

2．Components

① Frame

② ST core

③ RT core

④ ST coil

⑤ Bracket

⑥ Shaft

⑦ Ball bearing (at the pulley side)

⑧ Ball bearing (at the fan side)

⑨ Wave spring

⑩ Brake yoke

⑪ Cover

⑫ Eyebolt

(2) With brake (option)

1．Structure

The main motor is a shielded, outer-fan, 3-

phase, induction motor with integrated dc dry

single-plate excited-action brake.

2．Components

① Frame

② ST core

③ RT core

④ ST coil

⑤ Bracket

⑥ Shaft

⑦ Ball bearing (at the pulley side)

⑧ Ball bearing (at the fan side)

⑨ Wave spring

⑩ Brake yoke

⑪ Armature (braking disk)

⑫ Fan

⑬ Outer-fan cover

⑭ Cover

⑮ Eye bolt


M.2-2

(3) Braking operation

1．The brake always works while the weaving

machine is on halt after powering up.

2．Pressing the START switch or the inching

switch (FORWARD or REVERSE) cuts off

the braking power so as to degauss brake yoke

10 so that attracted armature 11 will be

retracted to the normal released position with

the attached leaf spring. Accordingly, the

brake will be released.

3．Power is applied to the main motor and the

machine starts running.

4．If the control box receives a stop signal, it cuts

off the motor power. At the same time, brake

yoke 10 is magnetized and attracts armature

11 to the shaft with more force than the

spring.

5．As a result, armature 11 is pressed against the

lining, whose frictional force generates

braking torque so that the motor quickly stops.


M.2-3

[1.3] Removal of Motor

(1) Without Brake

■ Removal procedure

1．Turn the machine power off.

2．Disconnect 11, 12, 101, and 103 wires

from the terminal board, U, V, W, X, Y,

and Z wires from the contactor, and E

(earth) wires from the grounding terminal

board in the control box.

NOTE: The two E wires should be discon-

nected at the last.

3．Remove the main motor from the weaving

machine and place it on the workbench.

■ Procedure of replacing bearings

1．Remove bolt 1 and take out outer cover 2.

2．Pull out fan 3.

・Key 4 of the aluminum-made fan is fixed

with an set screw.

Loosen the set screw to remove.

・Adhesive is applied to key 4 of the resin-

made fan.

Melt the adhesive with hot air and detach

it.

3．Remove bolt 5 and detach bracket 6 from

the body of the motor.

4．Remove the dust and fly that are attached to

parts with friction-powder compressed air.

5．Remove bearing 8 of shaft 7.

6．Reinstall the removed components with the

reverse order of the above steps.

NOTE:

・Make sure that all screws are not loose.

・Fasten bolt 5 with torque of 15N·m-

16N·m (150-160kg·cm) .

・Apply Three Bond 1322 to the set screw

at the area where the aluminum-made

fan is fastened.

Apply Aron Alpha #203 to the center of

the key slot of the resin-made fan.


M.2-4

(2) With Brake

■ Brake adjustment (option)

The initially set gap “a” between armature 1

and brake yoke 2 is 0.3 ± 0.05 mm. If the

gap “a” becomes wide, the attraction force

of the brake yoke for the armature weakens

when the brake is activated, so that the

timing from powering-off to machine stop

will drag out.

Accordingly, the stop position of the

machine will be beyond the specified

position.

In such a case, adjust the gap “a” with the

steps below:

■ Procedure of replacing bearings

1．Remove screw 1 and then outer cover 2.

2．Remove bolt 3 and then fan 4.

3．Remove bolt 5 and washer at the end of the

shaft and then pull out brake hub 6.

4．Remove key 7 from the shaft and pull out

shim 8 (2 pieces of thin plate, 1 piece of

thick plate, and 1 piece of collar).

5．Remove bolt 9 and then detach brake stator

10 from the main body of the motor.

NOTE: Be sure not to misplace wave spring

11.

6．Remove the dust and fly that are attached to

each part with friction-powder compressed

air.

7．Remove bearing 13 of shaft 12.

8．Reinstall the removed components with the

reverse order of the above steps.

NOTE:

・Make sure that all screws are not loose.

・Fasten bolt 7 with torque of 15N·m-

16NÅEm (150-160kg·cm) .

・Apply Three Bond 1322 to bolt 5.

・Adjust the gap as [0.3 ± 0.1]mm by

adjusting the position of the brake hub

using the *-marked shim.


M.2-5

[1.4] Replacement of Bearing

(1) Removing the bearing

1．With a press

Support the rotor 1 with inner ring 2a of the

bearing 2, then press shaft end A with a press

to take out the bearing.

2．With pull-out tools

・With a pulley pull-out tool commercially

available:

Hook pawls 3 onto inner ring 2a of the

bearing 2, then rotate handle 4 to take out the

bearing.

・With a special tool:

Make a special box tool, set shaft-box cover

5 against inner ring 2a of bearing 2, then

rotate handle 6 to take out the bearing.


M.2-6

(2) Reinstalling the bearing

Before reinstalling the bearing, apply oil to the

joint between the bearing interior and the motor

shaft.

NOTE: Set the bearing over the shaft perpendicu-

larly.

1．With a press

Apply pipe 7 having the same diameter as the

distance of inner ring 2a of bearing 2, to the

inner ring. Then, force-fit the bearing gently

with a press.

2．Without a press

Apply a pipe jig having the same diameter as

inner ring 2a of bearing 2, to the internal ring.

Then, drive in the bearing by tapping section

B gently with a hammer.

NOTE: Take care not to twist the bearing or let

the pipe jigs touch the seal and outer ring

of the bearing.

[1.5] Installation of Motor

(1) Install the main motor having new bearings onto

the machine.

(2) First, connect the two E (earth) wires to the

grounding terminal.

(3) Connect wires 11, 12, 101, and 103 to the

terminal board, then wires U, V, W, X, Y, and Z

to the contactor.

(All of these wires were disconnected in “■

Removal of Motor” procedure.)

(For towel weaving machines, connect wires U,

V, and W only to the contactor.)

■ Motor rotation direction and belt tension

Refer to Chapter 1, Subsections 1.1.3 and 1.1.4.


M.2-7

[2] Adjustment of Separate Brake

■ Adjustment of brake section

The initially set gap “a” between armature 1 and

brake yoke 2 is 0.5 ± 0.1 mm. If the gap “a”

becomes wide, the attraction force of the brake yoke

for the armature weakens when the brake is

activated, so that the timing from powering-off to

machine stop will drag out.

Accordingly, the stop position of the machine will

be beyond the specified position.

In such a case, adjust the gap “a” with the steps

below:

(1) Move the brake yoke fixed by four W-nuts (Nos. 1

through 4) shown by arrows in the figure to adjust

gap “a” of the separate brake.

(2) Adjust W-nuts so that gap “a” is 0.5 ± 0.1 mm.

(3) Put 0.5 mm shims equally on four sides between the

stator and armature, adjust the stator position with

the brake applied, and ensure gap “a”.


M.2-8

[3] Replacement of Weft-insertion-relatedComponents

[3.1] Air Filter

(1) Shut off the compressed air with cock 1.

(2) Turn cock 3 provided on the bottom of bowl 2

clockwise to release the residual pressure.

Expel air from the main and sub tanks. (This

operation is the same as for draining.)

Be sure to release the residual pressure at this

stage. If you proceed to steps (3) and (4) without

releasing it and attempt to remove bowl 2, the

residual pressure will blow off bowl 2 with a

powerful blast. It is dangerous.

(3) While supporting air filter plate 4 with your right

hand, hold bowl 2 with your left hand and press

the lower section of latch 5 with your left thumb.

(4) Turn bowl 2 clockwise until mark △ A on latch 5

is aligned with mark △ B on air filter plate 4,

then pull down bowl 2.


M.2-9

Air filter plate 4 becomes the shape as shown at the

left.

(5) Turn baffle 6 clockwise to remove it from air

filter plate 4.

(6) Separate element 8 and louver 7 from baffle 6.

(7) Replace element 8with a new one, or wash it with

household neutral detergent. (See NOTE below.)

After washing, blow air into the element to

remove moisture.

If water or oil accumulates in a short period of

time, inspect the compressor.

(8) Wash the inside of bowl 2with household neutral

detergent. (See NOTE below.)

(9) Replace O-ring 9 with a new one, or wash it with

household neutral detergent. (See NOTE below.)


M.2-10

(10) Assemble baffle 6, element 8, and louver 7, then

install the assembly into air filter plate 4 by

turning baffle 6 counterclockwise. (Refer to the

illustration in step (5).)

(11) While supporting air filter plate 4 with your right

hand, hold bowl 2 with your left hand and press

the lower section of latch 5 with your left thumb.

(12) Align mark △ A on latch 5 of bowl 2 with mark

△ B on air filter plate 4, then push up bowl 2 into

air filter plate 4.

(13) Turn bowl 2 counterclockwise until latch 5 is

fitted into cutout C provided in air filter plate 4,

then release your left thumb.

NOTE: After using household neutral detergent,

be sure to rinse it off throughly with

water.

NOTE: Do not use alcohol, kerosene, or gasoline

which will damage the plastic balls of the filters.


M.2-11

[3.2] Replacement of Electromagnetic Pin for EDP

(1) Turn the machine power off.

(2) Remove cover 6 and head cover 3 of the EDP

stand, and then disconnect wire 1a for the

electromagnetic pin Assy and wire 2a for balloon

sensor 2 from the connectors.

(3) Loosen bolt 4 securing electromagnetic pin Assy

1 to the EDP, and remove the Assy.

(4) Remove wind sensor 2 and plate 5.

(5) The electromagnetic pin body has a structure

shown above.

When four screws ① are removed, the Assy can

be separated as shown at the left. Parts subject to

replacement are core bushing② and spring③. At

this time, be careful so as not to lose spring

washers ④ and ⑤.


M.2-12

(6) When three screws⑥ are removed, parts may be

disassembled as shown at the left.

Parts subject to replacement are body bushing ⑦

and cushion rubbers ⑧, ⑨ and ⑩.

Be careful on the order of parts during reassem-

bly.

NOTE: Use the specific jig (No. J8211-01050-

00) for removing or mounting the body

bushing ⑦.

Combine the specific jigs as below.

Removing •••• (a), (b)

Mounting •••• (b), (c), (d)

Hammer (c) with a resin hammer at mounting.

Procedure of replacing body bushing

1．Pull-out

a. Insert the pull-out tool that is assembled into

the base.

NOTE: Make sure that the blade on the tip of

the tool does not touch inside of the

base.

b. Slightly press and then rotate it clockwise

(approx. 20 times).

c. Pull out the tool from the base.

d. Remove the body bushing and cutting power

on the blade.

NOTE: Be sure not to cut your hands with

the blade.

e. Remove the cutting powder on the base.


M.2-13

2．Installation

a. Attach the new body bushing to the

installation tool.

NOTE: Make sure that the direction of the

body bushing is correct.

b. Insert the installment tool that the body

bushing is attached to into the base.

c. Hammer the tip of the drift pin with a plastic

hammer.

d. Hammer the drift pin up to where the height

of the drift level becomes as same as that of

the guide.

e. Pull out the tool from the base.

f. Remove cutting powder on the base.

(7) Reassemble electromagnetic pin Assy 1 to the

EDP body.

NOTE: Adjust the gap with the length measure-

ment band 11 to the dimension shown in

the figure using the thickness gauge (No.

J8211-02011-00). Then, adjust position

of the band so that the plunger 7d is

located at the center of the hole in length

measurement band 11.


M.2-14

■ Replacement procedure for the electromagnetic pin and the plunger cap

The procedure below requires hot water of 95°C

to soften glue. Be sure to wear the protector

during this job.

Organic solvent and glue contain highly flamma-

ble ingredients. Keep them from fire to prevent

fire hazards.

Organic solvent and glue may damage your

skin, eyes, and respiratory system.

When using them, be sure to wear a protector,

safety gloves, safety goggles, etc.

Also, perform adequate ventilation, and wear a

gas mask, etc. as required to prevent direct

inhalation of volatile components.

Follow the handling instructions provided by the

manufacturers/sellers of the above materials.


M.2-15

(1) Remove assemblies of plunger body 1 and cap 2

from the electromagnetic pin ASSY.

(2) Soak the glued section sandwiched between the

plunger body and cap in hot water of 95°C to

soften the glue for 5 to 10 minutes. While it is

heated, remove cap 2.

(3) Wipe off the glue left on the plunger body with a

waste cloth moistened with organic solvent, such

as acetone.

(4) Mix glue.

Then, check that no bubbles are found in the glue.

(The glue should not be cloudy in white.) For

details on the directions for use, refer to the

instructions of the glue.

＜Recommended glue specifications＞

Manufacturer: Konishi Co., Ltd.

Product name: Bond E Set L

Main agent:hardener mixing ratio ＝ 1：1

(volume ratio)

＜Substitute glues＞

Manufacturer: Henkel

Product name: Loctite PC7210

Loctite Hysol E60-HP

Manufacturer: 3M

Product name: ScotchWeld DP460

NOTE:Use glue within 30 minutes after mixing.

(5) Degrease the plunger body and the interior of the

replacement cap with organic solvent. Leave them

for approximately one minute, and then check that

the organic solvent has volatilized.

NOTE: When wiping solvent off, do not use any

waste cloth contaminated with oil.


M.2-16

(6) Use a pointed stick, such as a bamboo skewer, to

thinly apply the glue that has been mixed in step

(4) on the entire circumference of the plunger

body tip.

(7) While rotating the cap, insert the plunger body.

When the plunger body is inserted halfway

through, take the plunger back by 1/4 of the cap

length. Then, insert the plunger body again until

the cap is level with the plunger body tip.

(8) Wipe off excessive glue with a waste cloth.

NOTE: Ensure that no glue is adhered on the cap

surface.


M.2-17

(9) Check that the cap is level with the plunger body

tip.

(10) Heat the assembled cap and the plunger body in a

drying furnace to heat-cure the glue.

(At 80°C for one hour or more within one hour

after glue application)

(11) After gluing is completed, reattach them to the

electromagnetic pin ASSY.


M.2-18

[3.3] Replacement and Honing of Upper andLower Blades of

Mechanical LH Cutter

The procedure below requires hot water of 95°C to soften Araldite (glue). Be sure to wear the

protector during this job.

(1) Remove assemblies of upper blade shaft 1 and

lower blade guide plate 2 from the cutter Assy.

(2) Soak the glued section sandwiched between the

upper and lower blades in hot water of 95°C to

soften Araldite for 5 to 10 minutes. While it is

heated, remove flat-head machine screws and

separate the upper and lower blades from each

other.

NOTE: Once removed, the flat-head machine

screws become unusable. Do not use

them again.

(3) To hone blades and use them again, refer to the

manufacturer’s instruction manual for honing

procedure.

After honing, remove excess Araldite adhering to

the blades, cutter shaft, and guide plate with a

cutter knife and the like.

Soak the adhesion faces of the upper and lower

blades in degreasing solvent, wash them with a

brush, and wipe them with a waste cloth.

NOTE: Do not use any waste cloth contaminated

with oil.

(4) Assembly of the upper blade

Make upper blade 3, cutter shaft 4, and flat-head

machine screw 5 (new part) ready for assembly,

all of which should be degreased.

(5) Preparing Araldite

Mix base material and hardener at a volume ratio

of 10:10 (at a weight ratio of 10:8).

(6) Apply Araldite to the adhesion face in the groove

of the cutter shaft uniformly and then glue upper

blade 3 and cutter shaft 4 together by sliding the

upper blade into the groove so that Araldite

becomes fitted with the adhesion face.


M.2-19

(7) Apply Araldite to the countersunk section and

internal thread of the screw holes and the external

thread of the flat-head machine screws.

NOTE: Do not apply Araldite to the countersunk

section of the flat-head machine screws.

(8) Tighten the two flat-head machine screws

alternately two times or more with a screwdriver.

Check that they are firmly tightened.

(Standard tightening torque: 0.27 to 0.30 N·m (2.

7 to 3.0 kg·cm))

NOTE: Wipe off excessive glue with a waste

cloth.

(9) Heat the assembled upper blade in a drying

furnace at 120°C for 25 minutes or more to heat-

cure Araldite.

(10) Assembly of the lower blade

Make lower blade 6, guide plate 7, and flat-head

machine screw 8 (new part) ready for assembly,

all of which should be degreased.

(11) Preparing Araldite

Mix base material and hardener at a volume ratio

of 10:10 (at a weight ratio of 10:8).

(12) Apply Araldite to the adhesion face of lower

blade 6 and then attach guide plate 7 to the face so

that Araldite becomes fitted with the adhesion

face.

NOTE: Apply Araldite to the hatched section of

the lower blade only as illustrated at left.

Do not apply Araldite to the whole

surface or the guide plate.

(13) Apply Araldite to the countersunk section and

internal thread of the screw holes and the external

thread of the flat-head machine screws.

NOTE: Do not apply Araldite to the countersunk

section of the flat-head machine screws.


M.2-20

(14) Tighten the two flat-head machine screws

alternately two times or more with a screwdriver.

Check that they are firmly tightened.

(Tightening torque: 0.27 N·m to 0.30 N·m (2.7 to

3.0 kg·cm))

NOTE: Wipe off excessive glue with a waste

cloth.

(15) Heat the assembled lower blade in a drying

furnace at 120°C for 25 minutes or more to heat-

cure Araldite.

(16) Install the assembled upper blade and lower blade

to the weaving machine, then adjust the contact

pressure between those blades.

(Refer to the adjustment procedure of the

corresponding cutter type given in Section 3.5.)

[3.4] One-touch Elbow (Pulling Out the Air Hose)

While pressing elbow’s release bushing 1 uniformly,

pull out air hose 2.


M.2-21

[3.5] Valve Inspection

Display the manual jet screen of each valve.

for main valves, press [ Map ] - [ Main ] - [ Manual ],

and for sub-valves, press [ Map ] - [ Main ] - [ Sub ],

Check the operation of each valve to confirm that the

valves turn on and off properly.

Valves are recommended to be checked once a month.

At the sub valve manual screen, valves that are not

used based on the set drawing width are grayed out.

Furthermore, if the current speed is set at the machine

opening angle, and the operation control [Exec] button

is pressed, valve injection is commenced at the same

time as actual operation.

[3.6] Valve Disassembly, Cleaning and Assembly Procedure


M.2-22

As a principle, replace the valve in the following

procedure when you find it faulty through inspection.

Frequency may differ by the conditions of the usage,

however, the bi-annual overhaul and the cleaning of

the valves are recommended for further safe and proper

use.

Concerning the exhaust valve of the sub valve, annual

overhaul is recommended.

Furthermore, if using the sub double blow function, it

is recommended that the sub-valve be overhauled

approximately once a year.

The following three components of the plunger block

shall be maintained with due care to keep the valve in

good condition.

・Guide rings ⑤ (GUIDE)

・Urethane seat (SEAT)

・Poppet (VALVE, POPET)

Replace the guide rings when their outer diameter is

reduced to 10.7 mm or smaller.

Replace the urethane seat when thinned down to 0.7

mm or less to avoid the end face come in contact with

the metal.

Replace the poppet if the valve has more backlash, or if

the seating surface is worn to cause air leak.

Especially, the guide rings of the cut blow valve may

wear out quickly due to the conditions of the air and

other factors. This valve is located outside the frame

and thus easy to maintain. Perform the maintenance of

the valve at least once a year.

At replacing the guide rings or urethane seats, it is

recommended that the springs are replaced as well.

Abrasion powder may be generated when the spring is

used for a long period, and such usage may accelerate

the abrasion of the parts such as guide rings.

In addition, the guide ring for the exhaust valve of the

sub valve may be worn out quickly according to the

conditions of the air.

Maintain valves at least once a year preferentially.


M.2-23

(1) Plunger cleaning work procedure

1．Fix the valve.

NOTE: Fix body so① as not to apply any load

to coil ⑧.

2．Disassemble coil ⑧.

Loosen nut ⑪, and remove washer ⑩, yoke

⑨, and coil ⑧.

NOTE:

・When loosening nut⑪, fix body so① as

not to apply any load to coil ⑧.

・Keep nut⑪, washer⑩, yoke⑨, and coil

⑧ so as not to lose them.

3．Disassemble plug ③.

Fit wrench securely onto parallel flat sides of

plug ③, and apply a force in the direction of

the arrow to remove plug ③ while holding

OC frame ⑦.

NOTE:

・Fix the wrench securely so as not to let it

slip from the flat sides of plug ③.

・Apply the force not gradually but at a

breath.

4．Disassemble the OC frame ⑦.

Slowly remove OC frame⑦from the body①

while holding plunger ④ with a finger to

prevent it from falling.

NOTE:

・Carefully prevent O-ring② from missing.

・Carefully prevent plunger ④ from falling

down.


M.2-24

5．Remove plunger ④ from OC frame ⑦.

NOTE:

・Carefully remove plunger ④ and OC

frame ⑦ so as not to lose them.

・Keep spring ⑥ carefully so as not to lose

it.

6．Clean plunger ④.

Use a soft shop cloth to wipe grease and

powder deposits on the outer side of plunger

④ and guide ring ⑤.

NOTE:

・Do not use any solvent for cleaning.

・Use a soft shop cloth for wiping so as to

prevent any damage.

・After cleaning, make sure that no deposit

remains there.

7．Clean OC frame ⑦.

Wipe grease and powder deposits on the inner

side of OC frame ⑦.

NOTE:

・Do not use any solvent for cleaning.

・Use a soft shop cloth to prevent any

damage.

・After cleaning, make sure that no deposit

remains there.


M.2-25

8．Check the movement of plunger ④.

Check that plunger ④ without spring ⑥

comes down by its own weight into OC frame

⑦.

Check by repeatedly changing the position of

plunger ④ a few times.

NOTE: If the plunger ④does not come

down by its own weight, repeat the

procedure from step 6).

9．Install spring ⑥ and OC frame ⑦.

Install spring ⑥ in the center on the spring

seat of OC frame ⑦.

After checking correct spring installation,

install plunger ④ on OC frame ⑦.

NOTE:

・After checking installation of spring⑥ in

the center on the spring seat of OC frame

⑦, install plunger ④.

・Do not install any spring⑥ that is bent or

curled.

・When installing plunger ④, do not press

the spring down forcibly.

10．Check installation of O-ring ②.

a．Check that O-ring ② is installed in the

groove of body ①.

NOTE: If deviated from the groove, correct

the installed position.

b．After checking O-ring②, fix body① with

a vice.


M.2-26

11．Install plug ③ and body ①.

a. With the plunger ④ in the plunger block

Assy facing upward, insert plug ③.

b. With the plunger ④ in the plunger block

Assy facing upward, install body① so as to cover

it.

NOTE: Carefully prevent O-ring② installed

on the body ① from falling down.

c. After installation, fix the plunger block Assy

and body ① with fingers and manually tighten

plug ③.

NOTE: Carefully prevent departure of the

spring from the spring seat (on either

the plunger or the OC frame side).

If assembled with the spring off

from the spring seat, damage may

result.

12．Install plug ③.

After manually tightening plug③ onto body

①, fix the body① in a vice and retighten the

plug with a torque wrench.

NOTE:

・Guideline of tightening torque: About 20

N·m

・Fit the torque wrench securely so as not to

let it slip from the parallel flats of plug③.

・This procedure is recommended to be

performed by the following torque wrench

and socket.

Parts number of torque wrench:

77105-00033-00

Parts number of socket:

77105-00034-00

13．Install coil ⑧ and yoke ⑨.

After installing coil ⑧, Install yoke ⑨.

NOTE: Install coil ⑧ in the correct

direction. See “External view by

model”.


M.2-27

14．Install washer ⑩.

NOTE: Carefully set the washer ⑩ in the

correct direction.

15．Install nut ⑪.

Tighten nut ⑪ with a wrench or other

appropriate tool.

NOTE: Nut ⑪ tightening torque: 5 to 6 N·

m. Do not over-tighten it.

(2) Guide ring replacement procedure

1．Carry out steps 1) to 5) of (1) “Plunger

cleaning work procedure”.

2．Remove guide ring ⑤ from plunger ④ by

hooking a nail on its notched portion.

3．Remove guide ring ⑤.

NOTE:

・Do not use a hard or sharp-edged tool like

a screwdriver to prevent plunger ④ from

damage.

・Carefully prevent the removed guide ring

⑤ from mixing with new ones.

4．Clean plunger ④.

Wipe grease or powder deposit from the outer

surface of plunger ④.




M.2-28

6．Apply grease on plunger ④.

NOTE:

・The recommended grease is SEALUB S-

14 (manufactured by KLUBER

Lubrication).

The greases listed as grease E category

(bulk greasing) in M3-3 [2], such as

Cosmo Grease Dynamax Super No. 0

(Cosmo Oil Lubricants Co., Ltd.) are also

applicable.

・Pay attention to the amount of grease to be

applied.

If applied excessively, malfunction may

be caused.

・If applied excessively, clean it once for

reapplication.

7．Install guide ring ⑤.




M.2-29

(3) Plunger block replacement procedure



2．Take the plunger block Assy from the bag.

NOTE:

・When taking it out, place plunger ④ on

the upper side.

・While taking it out from the bag, carefully

prevent its components from falling down.

Do not use any fallen component again.




M.2-30

■ External view by model

NOTE: Perform assembly with the lead wide of coil in the direction illustrated below.


M.2-31

[3.7] Procedure to Disassemble ABSSolenoid and Replace Parts

This section shows the procedure to replace parts of

ABS solenoid. (Refer to Fig. 1.)

The table 1 shows the component formation of the

solenoid.

Fig. 1: Assembly condition

(1) Disassembly

1．Remove the felt-F ① and the felt-R ⑧.

2．Remove the internal C-shape snap ring ② on

the shaft ø5 side.

3．Hit the shaft ø4 side lightly toward the shaft

ø5 side (upward in the exploded diagram), and

take out the rotor ④.

At the same time, pull off the drawn bearing

③ from the shaft ⑥.

NOTE:

・The bearing is fixed to the shaft joint with

low-strength anaerobic adhesive.

・Take extra care in taking out the rotor

from the ASSY and handling from taking

out to assembly (especially the permanent

magnet ⑤).

4．Remove the internal C-shape snap ring ②on

the shaft ø4 side, then pull off the bearing ③

from the shaft ø4 side.

Table 1: Solenoid (63452-00000-**) Component forma-

tion

No. Part nameTOYOTA

part numberQty

① Felt-F 63452-00012-** 1

② Internal C-shape snap ring 2

③ Bearing 696 ZZ 73269-06001 2

④ Rotor 63452-00011-** 1

⑤ Permanent magnet 1

⑥ Shaft 1

⑦ Main ASSY (coil + casing) 1

⑧ Felt-R 63452-00013-** 1


M.2-32

Fig. 2: The condition where adhesive is applied

(ø5 side)

Fig. 3: The condition where a bearing is as-

sembled (ø5 side)

(2) Assembly

NOTE: Remove foreign matters and dirt attached

to parts before assembly.

1．Apply low-strength anaerobic adhesive to the

bearing joint (ø6) as shown in Fig. 2, and fix

the bearing③ to the shaft ø5 side⑥ as shown

in Fig. 3.

NOTE:

・Degrease, clean, and dry the bearing joint

(ø6) of the shaft before applying adhesive.

・Apply adhesive thinly all around ø6, and

take care not to run it off to the bearing too

much.

・Press the bearing firmly so that it sticks

fast to the shaft ø8 stepped section (no gap

allowed).

2．Build the bearing③ onto the shaft ø4 side of

the ASSY, and install the internal C-shape

snap ring ②.

NOTE: Degrease the inner ring of the

bearing before assembly.

Fig. 4: The condition where adhesive is applied

(ø4 side)

Fig. 5: Adhesive check (ø4 side)

3．Apply low-strength anaerobic adhesive to the

inner ring of the bearing on the shaft ø4 side

as shown in Fig. 4, and mount a rotor ④.

Wipe off adhesive with cotton buds if it is

excessive as shown in Fig. 5.

NOTE:

・Apply adhesive thinly all around the inner

ring of the bearing.

・Clean the rotor before installing it.

Incomplete removal may cause a malfunc-

tion.

・Take extra care in handling the permanent

magnet.

4．Install the internal C-shape snap ring② on the

ø5 side.

NOTE: Double-check if the internal C-

shape snap ring is surely set in the

groove of the housing after installa-

tion.

5．Install the felt-F ① and the felt-R ⑧.

NOTE: Be careful of defective installation

such as wrong mounting location of

two types of felt (for ø4 and ø5) and

loose mounting.


M.2-33

[3.8] APC: Regulator with motor (option)

■ Poppet replacement procedure

EAG 1A-* (with motor)

Poppet ASSY

(1) Loosen cap 1, and then remove spring 2 and

poppet Assy3.

(2) Fit O-ring 7 to replacement poppet 6.

(3) Place poppet 6 and spring 2 on cap 1, and then

attach to body 4.

・Apply a tightening torque of 20 ± N·m (200

± 20 kgf/cm) to prevent damage to the O-ring.

・Ensure that the O-ring has not been damaged.


M.2-34

■ Diaphragm Assy replacement procedure

(1) Loosen screw 1, and then remove motor 2.

(2) Loosen bolt 3, and then remove body 4 and

diaphragm Assy7 while taking care not to drop

spring 9.

(3) Turn body 4 and diaphragm Assy7 the other way

round.

(4) Screw in adjustment screw 5 to align the end face

so that it is 27 mm from the spacer 6 motor side.

(5) Attach holder 8 and spring 9 to spacer 6.

(6) Place a new diaphragm 7 on spring 9 (pay

attention to the direction.)

・Ensure that the gap between diaphragm 7 and

spacer 6 is 4 mm.

(7) Attach spacer 6 to body 4.

・Apply a tightening torque of 3 ± 3 N·m (30

± 3 kgf/cm) to prevent damage to the

diaphragm.

(8) Attach motor 2 to spacer 6 and body 4 with bolt 1.

Tightening torque: 1.2 ± 2 N·m

(12 ± 2 kgf/cm)


M.2-35

■ Motor replacement

(1) Loosen screw 1, and then remove holder 2.

(2) Attach holder 2 to new motor 3.

Tightening torque: 0.83 ± 0.2 N·m

(8.5 ± 2 kgf/cm)

・Ensure that the holder and shaft are flush with

one another.

(3) Attach felt 4 to motor 3.


M.2-36

[4] Replacement of Selvage-forming related Components

[4.1] Leno Bobbin Holders

Check the components of the leno bobbin holder

approximately once a year to prevent the degradation

in the quality of the woven fabric, weft miss, false stop

due to abrasion or deformation of the components.

CHECK IF WHAT TO DO

1 Bobbin rod and bushings Worn Replace

2 Tenser arm bushings Worn Replace

3 Bobbin holder Deformed Repair or replace

4 Binding eyes Broken Replace

5 Tenser arm Deformed Repair or replace

6 SpringDeformed or

brokenReplace

7 Ratchet finger Deformed Repair

8 Bobbin rod stopperDeformed or

wornRepair or replace


M.2-37

(1) Replacement of bobbin rod bushings

1．Remove E-shape snap rings 9.

2．Remove worn bobbin rod bushings 1 with a

flat screwdriver.

3．Clean away all residue of glue from the

bushing mounting area on each side of bobbin

holder 10, then degrease the area with toluene.

4．Degrease new bushings.

5．Attach the bushings to bobbin holder 10 with

Super glue #401, then lock them with E-

shape snap rings 9 so that the snap rings

become parallel with the bottom line of holder

10 as shown at the left.

(2) Replacement of tenser arm shaft assembly

1．Remove nuts 3 from both ends of supporting

rod 2, then take out the supporting rod.

2．Remove nuts 4, inside springs, and other parts

from tenser arm shaft Assy 1.

3．Pull (expand) bobbin holder 7 outwards near

the tenser arm shaft, then remove tenser arm

shaft Assy 1.

4．Pull (expand) bobbin 7 of the tenser arm shaft

section outwards and fit in.

5．Reinstall parts replaced or removed in step 2)

above to the tenser arm shaft.

6．Apply Lock Paint to threaded sections of

supporting rod 2, then fix by tightening nuts 3

on the both ends.


M.2-38

7．Install leno bobbin 12 and check that end E of

ratchet finger 8 fully engages one of the

ratchet gears. Next, rotate leno bobbin 12 to

check that ratchet finger 8 works correctly.

NOTE: Make sure that the clearance

between leno bobbin 12 and the

bobbin holder 7 is 0.4 mm or less

and also is even. Check that the

bobbin rotates smoothly.

8．Move tenser arm 5 until the distance between

5 and binding eye 13 comes to approx. 11

mm, then check that ratchet finger 8 becomes

free from the ratchet of leno bobbin 12.


M.2-39

[5] Cleaning of Reed

Since the reed wind pressure is changed by the oil of yarn during weaving with filament warp, cleaning the reed at every

warp-beam change will stabilize picking.

The contaminated reed may adversely affect the quality of any woven fabric and the operation rate of the machine;

therefore, be sure to clean the reed before it is stored or reused. When the dent material is SUS420J2, the dent must be

cleaned periodically to prevent corrosion (rust) caused by contamination.

[5.1] Cleaning the Reed on the Machine

(1) Front of the reed

1．Loosen the warp tension, by referring to

Chapter 3, Subsection 3.1.3, [ 3.2 ] “Cloth

reverse”.

2．Set the crank angle at approx. 180°(the reed

placed at the rearmost position), by using the

tool handle.

3．Press the emergency stop button down until it

locks itself and the machine.

4．For reflecting weft feelers (for non-cut reed),

cover each of the weft feelers 1 with caps 2.

For penetrating weft feelers (for cut reed),

take out the weft feelers from the machine. (If

the reed cleaner adheres to the penetrating

weft feelers, the feeler's sensitivity will

diminish.)

5．Put rods 4 on warps 5 at the front and rear of

reed 3 to lower warps 5.

NOTE: Take care not to break warps.

6．Put some sort of shield 7 between healds 6 and

reed 3 over the full width.

7．Apply the reed cleaner on the front surface 3a

of the reed.

8．Gently wipe front 3a with a cloth.

NOTE: If the reed is very contaminated, use

a soft brush.


M.2-40

(2) Back of the reed

1. Remove rods 4 and increase the warp tension.

2. Release the locked emergency stop button.

3. Set the reed to the front side.

4. Press the emergency stop button down until it

locks itself and the machine.

5. Loosen the warp tension.

6．Put rods 4 on warps 5 at the front and rear of

reed 3 to lower warps 5.

7．Apply the reed cleaner on the back surface 3b

of the reed.

8．Gently wipe the back 3b with a cloth.

NOTE: If the reed is contaminated so much,

use a soft brush.

9．Increase the warp tension.

10．Release the locked emergency stop button,

then run the machine.

11．When the stained section of the warps

reaches temple bar 8, stop the machine.

12．Press the emergency stop button down until

it locks itself and the machine.

13．Gently wipe both the front 3a and back 3b of

reed 3 with a cloth.

NOTE: If the reed is still contaminated, use

the ultrasonic cleaning.

14．Release the locked emergency stop button

and run the machine.

(3) Cleaning fluid

Use the fluid recommended by the reed manufac-

turer or the equivalent (kerosene type).

Don’t use any cleaning fluid that would damage

plastics or reed.

Reed maker Product name of the reed

cleaner

Takayama Reed Co., Ltd. TR200A

Kiji Reed Co., Ltd. Neo Clean KS


M.2-41

[5.2] Cleaning the Reed Removed from theMachine, Using Ultrasonic

Cleaner(before Storage)

(1) Wash out fly, size particles, oil, and other stains

from the front and back of the reed with a brush.

(2) Put the reed into the ultrasonic bath and clean it.

NOTE: Refer to the Instruction Manual issued by

the manufacturer for the correct cleaning

agent type, density, and temperature, the

cleaning time, and the directions.

The illustration given at left shows the ultrasonic

cleaner which has the following components:

1: Ultrasonic generator

2: Reed

3: Cleaning bath

4: Heater

5: Control panel

(3) Take the reed out of the cleaning bath and gently

wash both sides of the reed with water.

(4) Dry the reed at room temperature or with a hot

blast of 50°C or less.

NOTE: Do not apply any hot blast of more than

50°C; otherwise, the dent will become

damaged.

NOTE: When the dent material is SUS420J2,

moisture remaining on it may cause

corrosion (rust). Blow air carefully to

remove moisture.

(5) Check the reed quality. If any defective or stained

section is found, repair or clean it.

(6) Wipe the entire reed with a dry cloth.

(7) Put each of the reeds in a plastic bag and store

them in a carton.

NOTE: Punch some holes in the plastic bag to

wick moisture.

(8) In a cool and dry place, place the cartons in

storage as illustrated at left away from heat (40 ℃

or above), moisture, and direct sunlight.


M.2-42

[6] Repairing of EDP Ceramic Piece

[6.1] How to Judge Whether the CeramicPiece is Reparable or Not

Judge whether the EDP ceramic piece is reparable or

not, according to the samples given below:

(1) Reparable damage

・Small chip a)

Max. reparable chip size:

1 (W) × 1 (L) × 1 (D) mm

(2) Irreparable damage

・Large chip b)

・Crack c)

・Split d)


M.2-43

[6.2] How to Repair

Repair the 10 mm area around the chipped section with a file or a hand drill according to the steps below.

■ Repairing with a file

Tools:

Rough filing ...Diamond file

(Metal #360 or equivalent)

Finish filing ...Diamond file

(Resin #800 or higher)

(1) File off the 10 mm area A (“a” = 10 mm) around

the chipped section with a rough file until the

chipped section becomes unnoticeable.

(2) Touch up the filed section with a finishing file.

■ Repairing with a hand drill

Tools:

Rough filing ... Diamond tool

(Metal #360 or equivalent)

Finish filing ... Felt buff and abrasive

(Diamond powder with 9μ

grid)

(1) File off the 10 mm area A (“a” = 10 mm) around

the chipped section with a rough-filing tool until

the chipped section becomes unnoticeable.

(2) Apply diamond powder to the filed section and

touch it up with a felt buff.


M.2-44

[7] Replacing the Inverter’s Capacitorsand Cooling Fans

(1) Smoothing capacitors

The smoothing capacitors for the inverter should be replaced with new spare capacitors every 5 years due to the

service life.

It is recommended that you place an order for the spare capacitors when the replacement time is close. This is

because capacitors stored more than 3 years require aging before use and the aging is difficult at your site.

(2) Electrolytic capacitors

The electrolytic capacitors on the inverter board should be replaced every 5 years.

It is recommended that you set up a spare inverter board when the replacement time is close, replace the inverter

board with the spare, and send it to TOYOTA for repair.

For the details about the inverter replacement parts, refer to the instructions manual issued by the inverter

manufacturer.

(3) Cooling fans

In the inverter box are cooling fans which should be replaced at the intervals of 2-3 years as a unit of complete

assembly due to the service life of bearings used.

NOTE: For details on the inverter replacement parts, refer to the instruction manual provided by the inverter

manufacturer.


M.2-45

M.2.2 Blower Motor(for Filament or Glass Fiber)

Be sure to check that the main switch is turned

OFF before connecting the blower motor leads.

■ Tightening torque of blower motor leads

When connecting the blower motor leads to the

terminals inside the terminal box, tighten the

mounting nuts to a torque of 0.8 to 1.2 N·m (8 to 12

kgf·cm).

Applying excessive torque may break the terminal

board.

M.2.2 Blower Motor(for Filament or Glass Fiber)

M.2-46

M.2.3 Replacement of Felt, FeltStopper, and Body

Bushing(Glass Specification)

(1) Hold the body Assy with a hand, set the felt

stopper/bushing removal jig, and drive the head of

the jig (shown by the arrow in the figure) with a

plastic hammer to remove the body bushing, felt,

and felt stopper.

(2) After removing the parts, blow air to remove foreign

matters completely.

NOTE: Carefully remove foreign matters thor-

oughly since insufficient removal may

adversely affect the performance.

(3) Set the body to bushing press-fitting jigs B and C.

With the chamfered side facing down, use press-

fitting jig A and press-fit the body bushing onto the

body.

At the time of pressing in, align the upper face of the

body bushing with the [X] plane. Since rapid

pressure application may deform the inside diameter

of the body bushing, use a hand press or the like to

apply pressure gradually for press-fitting.

After pressing in the body bushing, blow air to

thoroughly remove foreign matters and apply

CRC3-36 on the inside surface of the body bushing.

M.2.3 Replacement of Felt, FeltStopper, and Body Bushing(Glass Specification)

M.2-47

(4) Replace jigs with bushing press-fitting jig C and felt

stopper press-fitting jig E. Set the body with

bushing. With the chamfered portion of the felt

stopper facing down, press in the felt stopper using

felt stopper press-fitting jig D onto the body.

At the time of press-fitting, set the upper face of the

felt stopper (0 to 0.5 mm) below the [Y] plane. If

press-fitting is insufficient (above the [Y] plane), the

felt stopper may be caught by a yarn during loom

running to cause broken yarn or felt stopper

departure.

On the other hand, sudden pressurizing may deform

the felt stopper. Use a hand press for gradual

pressing.

After press-fitting the felt stopper, carry out air

blowing for perfect removal of foreign matters and

burrs.

REFERENCE:

Refer to Section G.2 “Tools” for the details of

jigs.

REFERENCE:

As for maintenance other than the felt and felt

stopper, refer to subsection M.2.1 [ 3.2 ].

M.2.3 Replacement of Felt, FeltStopper, and Body Bushing(Glass Specification)

M.2-48

M.2.4 Replacement of Metal Parts ofCloth Roller

Wheel ShaftBracket

[1] Pulling Out the Metal Parts

Metal pull-out jig (iron)

(1) Remove the related parts and bracket 1 from the

weaving machine.

(2) Wipe off grease from bracket 1 with waste cloth.

(3) Set bracket 1 to a vise and remove right and left

metal parts 2 with any metal pull-out jig (to be

prepared by you).

[2] Forcing in Metal Parts

(1) Force metal parts into bracket 1.

(2) Install bracket 1 and the related parts to the weaving

machine.

(3) Set the manual greasing nipple into the centralized

lubrication hole (PS1/8) and apply grease with a

manual pump.

(4) If grease comes out from both ends of bracket 1,

remove the manual greasing nipple and connect

lubrication pipe 3 instead.

M.2.4 Replacement of Metal Parts ofCloth Roller Wheel ShaftBracket

M.2-49

M.2.5 Maintenance of Valve forTucker

[1] Parts Structure

① Coil ASSY with DIN connector

② Hexagon socket head cap screw (M3 × 45)

③ Spring 74212-00810

④ Holder ASSY (⑤⑥⑦)

(XT323-16-20)

74212-00815

⑤ Holder

⑥ O-ring (18.79 × 16.79 × 1) 74212-00817-00

⑦ O-ring (13 × 11 × 1) 74212-00818-00

⑧ Plunger ASSY

(XT323-16-16)

74212-00814-00

⑨ Body set (⑩⑪) 74212-00816-00

⑩ Body

⑪ O-ring (19 × 16 × 1.5) 74212-00811

⑫ U nut

Grease for maintenance

(Use Grease No.2 of lithium series)


M.2-50

[2] Disassembly

(1) Loosen hexagon socket head cap screw and remove

coil ASSY.

Opposite sides of hexagon 2.5 mm

(2) Remove the spring.

REFERENCE: Holder tightening tool

(3) Remove holder ASSY using 4 holes on the holder

upper surface.

(Refer to Section G.2 “Tools”)

(4) Remove plunger ASSY.


M.2-51

[3] Assembly

(1) Apply grease to plunger.

Take care about the amount of coating.

(2) Put O-ring (18.79 × 16.79 × 1) to the side of

holder and set plunger ASSY.

(3) Screw holder into body.

(Refer to [ 2 ] “Disassembly”, (3))

REFERENCE:

Tightening torque 1 N·m

(4) Put U nut to the back side of the body. (2 places)

NOTE: Take care that there are front and back sides

of each U nut.


M.2-52

(5) Place O-ring (13 × 11 × 1) on the upper surface

of the holder with grease.

(6) Apply grease in a thin layer to the whole spring.

(7) Put spring into the hole in the coil ASSY and set coil

ASSY to body.

(8) Fix body and coil ASSY with Hexagon socket head

cap screw.

REFERENCE:

Opposite sides of hexagon 2.5 mm

Tightening torque 0.59 N·m

(9) Apply grease to O-ring (19 × 16 × 1.5) and put

O-ring the back side of the body.


M.2-53

M.2.6 Tucker Cutter Maintenance

(1) Remove the tucker cutter, disassemble, and carry out

maintenance roughly once a month.

NOTE: Replace J5304-46050-00 if there is play in

the shaft.

(2) The tucker cutter can be disassembled by loosening

nut 7.

(3) Following disassembly, clean any dirt from the fly

and so on, and then check the following.

・Replace the blade with a new one if scratched or

chipped.

・If the fixed blade 3 step is worn as shown in the

diagram on the left, replace fixed blade 3 with a

new one.

(4) Apply grease with a brush to the locations shown in

the diagram on the left.

・Cutter shaft 4 shaft periphery

・Spring washer 6/moveable blade 2 contact surface

・Moveable blade 2/collar 5 contact surface

・Moveable blade 2/fixed blade 3 contact surface

(5) Following grease application, apply Loctite to nut 7

and attach.

Apply a spring-balancer as shown in the diagram on

the left, pull downward, and adjust the nut 7

tightness so that the tucker cutter moves when 8 to

10 N (0.8 to 1 kgf) is applied.

M.2.6 Tucker Cutter Maintenance

M.2-54

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