Take up lever hitting frame

[sroot3485]

I had a problem while sewing a visor. I got machine back together but now the needlecase jams when trying to change colors. I think I have located the problem but don't know how to fix it. When I try to rotate the z axis it rotates only so far till the take up lever hits the frame above it. Is there a timing adjustment for this. I can see that it is not allowing the reciprecator to raise the needle high enough to stay in track causing the needlecase to bind. Thanks in advance

[Rod or Sharon]

sroot,

You said..."I got the machine back together...." That leaves a lot of guessing on what may be the problem. You also said....." I had a problem while sewing a visor"..... What kind of a problem?

Is this a Big Red or an XT?

Does a needle line up with the needleplate hole?

Did you remove one or both of the black upper arm covers that are behind the needlecase? If so, were they reinstalled so that the tracking groves lined up properly with each other? If not the needlebar studs may be coliding off center of the opposing cover as the needlecase tries to move

Can you manually raise and lower the active needlebar with your fingers with the machine on and the E-stop released?

By saying that " I can see that it is not allowing the reciprecator to raise the needle high enough to stay in track causing the needlecase to bind. Thanks in advance....."

This indicates that you have a needlebar stud that is either on top of or underneath of the the reciprocator jaws. The needlebar stud "must" be captured between the reciprocator jaws for it to raise and lower the needlebar. Another possibility is that either the upper or lower portion of the reciprocator jaw is broken off.

More information is needed to determine what has happened to you machine.

Rod Springer
Amaya Tech & Trainer

[sroot3485]

Thanks for getting back to me so quick.

Machine is a Big Red. I was sewing a visor when the needle jammed into the needleplate. This caused a needle to drop. I don't know how it caused that but it did. I got the needle back on the track after some doing.

I can get the needle lined up with needleplate hole and push it up and down but it jams the needlecase on any color change. It jams in either direction you try to move needlecase.

I did take off the right cover to check pressor foot and reciprecator. I still have it off so I can view what is happenig while I try to cycle the Z axis with the Estop tripped. This is how I noticed the pull up arm hitting the frame above it and stopping me from cycling the Z axis.

The needlebar stud is in the jaws of the reciprecator and both top and bottom jaws appear to be fine.

I also pushed needlebar past #1 and cycled Z axis by hand without a catch with no needle in position.

As I said, when I try to cycle the Z axis bar, it stops when the take up arm hits the frame above it and therefore stopping the reciprecator from cycleing to the top.

Hope this info helps.

[Rod or Sharon]

More questions......

How often do you aggressively blow out the needlecase color index and home sensors with compressed air on the Big Red?

With "all" of the needlebars in their up position, do "all" of the takeup levers line up "exactly" with each other? The active needlebar will be slighly down, maybe an 8th of an inch or so which is normal.

What happens when you go into Maintenance, Head Timing and try to do a "Headup" command?

The off color index and the needle colliding with the needle plate was more than likely from the color index sensor being contaminated altho, the needlecase will not move if the laser part of the sensor is not able to detect blocked and open positions. In some cases with the Home sensor,the needlecase may have a run-a-way because it can not find it's home position.

There is now the possibility that "if" you can not get both the takeup levers and the needlebars to each line up respective to them selves...that is....needlebars all up and takeup levers lined up exactly with each other....both of these at the same time.....then, the main drive gear that meshes with the takeup levers may have been shifted and is now coliding with the upper casting of the machine.

I hate to say it, but you may be in line for that dreaded tech call to get everything lined back up and timed correctly....

Rod Springer
Amaya Tech & Trainer

[sroot3485]

I made sure sensors are blown clean.

All of the needlebars are consistant with all being up and active slightly lower.

I acutally can restart machine now and it will cycle through the needlebars but when it gets where it's going I get a head not up error.

When I go to Heat Timing it make a turning type sound but nothing happens. Like something is spinning. Then a Z axis timeout errot.

Home does nothing because of the Z axis error.

[Rod or Sharon]

sroot,

I will assume that the takeup levers are "all" lined up exactly with each other and "with all" of the needlebars in the up position???

If so....this now is beginning to sound more like a Z-axis motor poblem with the new information you are giving me. If not, then what you said earlier would/could apply to the cause of the Z-axis time out error. If the main gear that meshes with the takeup lever gear is hitting the machine casting , a Z-axis timeout would definitly come into play, as the Z- axis is coming up against a solid stop.

But, but, but....the root cause of all this may now lie in the Z-axis motor itself. It is time to remove the upper left "transparent red" plastic cover. The Z-axis motor is located in the upper left rear corner of the machine.

Carefully inspect to see if there is any blackish redish dust present around and under the motor belt and pully. If you take hold of the pully, can you wobble it around....it should be solid with no movement If there is, the motor bushing/bearing in the front of the motor is shot and the machine should not be run or for that matter even turned on again until the motor is replaced. A failure of the Z-axis motor is notorious for taking out the Main motherboard when they go.

If there is no wobble or blackish/redish dust present, is the belt over the motor pulley tight with approxing 7/8 inch deflection? Is the screw that holds the pully on the shaft tight or loose allowing the pully to slip? Inside of the pully are colaspable star washers, tightening the screw will expand these washers inside of the pully cylinder. Tighten them too much and they collapse inward thereby releasing their grip and allowing the pully to slip. An inch ounce torque wench is used to apply only 8 inch ounces of torque to this screw, which is not much. Locktite is used to help prevent the screw from coming loose.

New Z-axis motors have been improved aand have a
roll pin placed thru the pully and motor shaft to avoid the above problem from developing. The Big Red with their original Z-axis motors did not have this feature.

Check these items out and let me know what you find....ok? It still may be time for that dreaded tech call to come into play ;-(.......

Rod Springer
Amaya Tech & Trainer

[sroot3485]

The screw was out of pulley and the pulley is slipping on the shaft. A little reddish brown dust below but not much. I put it back in but pulley is still slipping on shaft.

[sroot3485]

I don't see any star washers either

[Rod or Sharon]

sroot,

Any brown/redish dust should be taken as a warning that the motor bushing/bearing is on its way out and when it goes, it may take the main motherboard with it.

The screw is out of the pully....is it missing? Has the Z-axis motor been replaced in this machine? Does it have a pin thru the pully holding it onto the motor shaft? If there "is" a pin, then the screw will not be present in the newer motors.

You will not see the star washers unless the pully is removed from the motor shaft. They are "inside" of the pully body and as the screw is tightened it expands the washers inside of the pulley body to keep it from slipping.

You have found the "root cause" of your problem. Can you feel """any""" play in that Z-axis motor shaft? The redish/blackish dust is truly a concern and a warning of things to come. A picture would be helpful at this point.

[email protected]

Rod Springer
Amaya Tech & Trainer

[sroot3485]

The screw actually fell on floor when I removed the cover. I am inclined to think it came loose as a result of not being able to freely turn the Z axis shaft. When I turn it using the motor pulley it binds on the take up lever for the active needle as it hits the frame above it. If you try to go through the 360 rotation the take up lever that is binding actually forces the take up lever shaft to flex and lower the other take up levers as it clears the frame. I took pictures of take up lever. Is there a way to post them here?

[Rod or Sharon]

No....that is why I gave you my email address.

[email protected]

And no again....that screw did not come loose as a result of trying to turn the Z-axis shaft.

You still have not answered the question...you "must" be able to get all the needlebars up AND all of the takeup levers to line up exactly with each other ALL at the same time. Can you do this?

Rod Springer
Amaya Tech & Trainer