OPERATING MANUAL

(Translation of the original operating manual)

Programmable industrial sewing machine

Konrad Busche GmbH & Co. KG

Industriestrasse 70

D-70565 Stuttgart
Phone +49 (0) 711 7 80 67-0
Fax +49 (0) 711 7 80 27 85
E-Mail info@busche-online.de
Internet www.busche-online.de

Keep for future use!

 Machine/System Programmable industrial sewing machine
Year of manufacture: 2016

Operating manual for programmable industrial sewing machines:

Machines of the JUKI brand:
AB series AMB series ABF series
APW series LBH series LK series
MEB series MB series ASN series
MHB series MOL series AP series
AC series AE series AMS series without
enlarged sewing
area

Machines of the ASS brand:

BASS series

Machines of the MITSUBISHI brand:

PLK series

Machines of the ADLER brand:

Kl.30 series

Machines of the BROTHER brand:

PR600 series PR1000 series

Machines of the STYRTEKNIK brand:

HECTOR series WANDA series
Version 01

Edition: December 2016

© Konrad Busche GmbH & Co. KG

This operating manual and all illustrations contained herein are protected by copyright. Any use
outside the limitations of copyright law without our prior written approval is prohibited and liable to
prosecution. This applies especially to reproduction, translation, microfilming, saving, and editing in
electronic systems.
Contents
1 Introduction ........................................................................................................................... 1
1.1 Notational conventions ........................................................................................................... 2
1.1.1 Section-related safety instructions ............................................................................ 2
1.1.2 Embedded warnings ................................................................................................... 3
1.1.3 Other notational conventions .................................................................................... 3
1.1.4 Symbols used in the manual....................................................................................... 4
1.2 Warranty and liability .............................................................................................................. 5
1.3 Copyright.................................................................................................................................. 6
1.4 Guarantee terms ...................................................................................................................... 6
1.5 Service / Customer service ...................................................................................................... 6

2 Safety ..................................................................................................................................... 7
2.1 Intended use ............................................................................................................................ 8
2.1.1 Structural alterations to the machine ........................................................................ 9
2.1.2 Foreseeable misuse .................................................................................................... 9
2.2 Personnel requirements ........................................................................................................ 10
2.2.1 Responsibilities ......................................................................................................... 11
2.2.2 Obligations of personnel .......................................................................................... 11
2.2.3 Unauthorised persons .............................................................................................. 11
2.2.4 Instruction ................................................................................................................ 12
2.3 General safety information.................................................................................................... 12
2.4 Safety measures for environment protection ....................................................................... 13
2.5 Special types of warning ........................................................................................................ 14
2.5.1 Symbols used on the machine .................................................................................. 14
2.5.2 Hazards due to electricity ......................................................................................... 14
2.5.3 Pneumatic power hazards ........................................................................................ 16
2.5.4 Laser hazard (when using an optional laser) ............................................................ 17
2.5.5 Sharp edge hazards .................................................................................................. 18
2.5.6 Hazards due to hot surfaces ..................................................................................... 18
2.5.7 Hazards due to incorrect spare parts ....................................................................... 18
2.6 Personal protective equipment ............................................................................................. 18
2.7 Safety devices and guards ..................................................................................................... 19
2.8 Information for emergencies ................................................................................................. 20
2.9 Obligations of the plant operator .......................................................................................... 21

3 Description of the machine ................................................................................................... 23

3.1 Overview ................................................................................................................................ 23
3.1.1 Overview of function elements ................................................................................ 23
3.1.2 Overview of operator controls ................................................................................. 24
3.1.3 Overview of guards................................................................................................... 25

Programmable industrial sewing machine I

 Contents

3.1.4 Rating plate .............................................................................................................. 25

3.2 Function description ............................................................................................................. 26
3.3 Technical data ....................................................................................................................... 26
3.3.1 Dimensions and weights of the lower parts ............................................................ 26
3.3.1.1 PV-ST100RO75.......................................................................................... 26
3.3.1.1 GVU-80-2RO ............................................................................................. 26
3.3.1.1 PZ100 ........................................................................................................ 26
3.3.1.1 KB12-80 .................................................................................................... 26
3.3.2 Connection data/performance ................................................................................ 27
3.3.3 Material ................................................................................................................... 27
3.3.4 Airborne noise emissions......................................................................................... 27
3.3.5 Environmental conditions........................................................................................ 27
3.3.6 Features ................................................................................................................... 28

4 Transport and storage ........................................................................................................... 29

4.1 Inspection by the recipient on handover .............................................................................. 29
4.2 Information about transport hazards ................................................................................... 29
4.3 Intermediate storage ............................................................................................................ 30

5 Installation ............................................................................................................................ 31
5.1 Information about installation hazards ................................................................................ 31
5.2 Preparations .......................................................................................................................... 31
5.3 Choice of installation site ...................................................................................................... 31
5.3.1 Necessary operating and maintenance space ......................................................... 31
5.3.2 Floor requirements .................................................................................................. 32
5.4 Connecting the power supply ............................................................................................... 32
5.4.1 Power supply ........................................................................................................... 32
5.4.2 Connecting the compressed air supply.................................................................... 32

6 Commissioning ...................................................................................................................... 33
6.1 Safety measures to be taken before commissioning ............................................................ 33
6.2 Setting up the height adjustment (optional) ........................................................................ 34
6.2.1 Mechanical height adjustment ................................................................................ 34
6.2.2 Electrical height adjustment .................................................................................... 34

7 Operation ............................................................................................................................. 35
7.1 Safety measures during normal operation ........................................................................... 35
7.2 Switching the machine on and off ........................................................................................ 37
7.3 Sewing operation .................................................................................................................. 38
7.4 Changing the needle ............................................................................................................. 38
7.5 Changing the thread.............................................................................................................. 38
7.6 Changing the spool................................................................................................................ 38

II Konrad Busche GmbH & Co. KG

Contents

8 Fault ..................................................................................................................................... 39

9 Maintenance ........................................................................................................................ 41
9.1 Safety measures when carrying out maintenance ................................................................ 41
9.2 Inspection and maintenance work ........................................................................................ 42
9.2.1 Maintenance intervals .............................................................................................. 42
9.2.2 Preparations ............................................................................................................. 43
9.2.3 Maintenance – daily operations ............................................................................... 43
9.2.3.1 Visual inspection and cleaning .................................................................. 43
9.2.4 Maintenance – annual .............................................................................................. 44
9.2.4.1 Inspect the screw fittings .......................................................................... 44
9.2.4.2 Pneumatic components ............................................................................ 44
9.2.5 Special maintenance intervals .................................................................................. 45
9.2.5.1 Pneumatic hoses (every 10 years at the latest) ........................................ 45
9.2.5.2 Replacing the lubricating oil...................................................................... 45
9.2.5.3 Edge cutting unit (optional) ...................................................................... 46

10 Decommissioning and dismantling .......................................... Fehler! Textmarke nicht definiert.

10.1 Disposal .............................................................................. Fehler! Textmarke nicht definiert.

11 Annex ................................................................................................................................... 48
11.1 EC Declaration of conformity ............................................. Fehler! Textmarke nicht definiert.
11.2 Documents in the annex: ....................................................................................................... 49

Programmable industrial sewing machine III

1 Introduction
This operating manual provides all the information you need to smoothly operate the
Programmierbare Industrienähmaschine (called machine from now on).

All persons responsible for operating, maintaining, cleaning and troubleshooting the
machine must read, understand and comply with the operating manual. This applies in
particular to the safety information that is given.
After reading the operating manual you will be able to

– operate the machine safely,

– maintain the machine according to the rules,

– clean the machine according to the rules and

– take the necessary action in the event of a fault.

In addition to this operating manual, it is necessary to comply with the general laws and
other regulations concerning accident prevention and environmental protection in the
country of use.
The operating manual must always be kept at the machine's point of deployment.

Programmable industrial sewing machine 1

 1 Introduction

1.1 Notational conventions

Passages of this operating manual that require special attention or are a direct hazard
warning are shown as follows:

1.1.1 Section-related safety instructions

Section-related safety instructions are not limited to just one specific action, but apply
to all the actions performed within a section.

Structure

SIGNAL WORD
Type and source of danger
Possible consequence(s) of failure to comply

Symbol – Measure(s) to avoid the danger

that
describes
the danger
in more
detail

Danger levels

DANGER
Hazard with a high level of risk which if not avoided can lead to death or
serious injury.

WARNING
Hazard with a medium level of risk which if not avoided can lead to death
or serious injury.

CAUTION
Hazard with a low level of risk which if not avoided can lead to negligible
or moderate injury.

2 Konrad Busche GmbH & Co. KG

1.1 Notational conventions

NOTE
Hazard with a low level of risk which if not avoided can lead to damage to
property.

1.1.2 Embedded warnings

Embedded warnings apply to specific actions and are integrated directly in the action.

Structure

SIGNAL WORD Type and source of danger

Possible consequences of failure to comply
– Measures to avoid the danger

Danger levels

– DANGER / WARNING / CAUTION (see section 1.1.1)

– NOTE (without warning triangle, see section 1.1.1)

1.1.3 Other notational conventions

The information symbol is followed by useful information.

– Text following this mark represents an item in a list.

 Text following this mark describes actions to be performed in the specified order.
"" Text in double quotation marks refers to other chapters or sections.

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 1 Introduction

1.1.4 Symbols used in the manual

Particular hazards in connection with hazard warnings are shown in addition as follows:

Fatal injury hazard due to electricity

This symbol warns of a life-threatening electrical hazard.
Touching live parts poses a direct risk of death.

Hazard due to suspended loads

This symbol warns of hazards due to suspended loads.
There is a considerable injury hazard when standing under suspended
loads.

Danger of hand injuries

This symbol warns of hand injury hazards.
Fingers and hands may be crushed.

4 Konrad Busche GmbH & Co. KG

1.2 Warranty and liability

1.2 Warranty and liability

The obligations under the supply contract, the general and delivery terms and conditions
of the machine and the legal regulations in force at the time the contract was signed will
apply.

All information in this operating manual has been compiled in line with the applicable
standards and regulations, the state of the art, and our longstanding knowledge and
experience.

Warranty and liability claims for personal injury and material damage are excluded if
they are attributable to one or more of the following causes:

– Unintended or inappropriate use of the machine

– Inappropriate installation, commissioning, operation, maintenance or cleaning of the

machine

– Operation of the machine with defective safety devices or with improperly fitted or
nonfunctional safety devices and guards

– Failure to heed information in the operating manual regarding installation,

commissioning, operation, maintenance and cleaning of the machine
– Deployment of non-qualified personnel who have not been provided with adequate
instruction for the tasks concerned.
– Structural alterations to the machine (conversions or other alterations to the
machine are not allowed to be made without prior written permission from
Konrad Busche GmbH & Co. KG. any breach of this causes the machine to lose its EC
conformity)

– Improperly executed repairs

– Use of nonpermitted spare parts or of spare parts that do not satisfy the technically
established requirements
– Disasters, effects of extraneous elements and force majeure

We reserve the right to make technical alterations in the course of further development
and improvement of features.

Programmable industrial sewing machine 5

 1 Introduction

1.3 Copyright
This operating manual is protected by copyright and intended for internal use only.
This operating manual or parts thereof must not be passed or disclosed to any third
party or be reproduced or exploited in any form without the prior written consent of
Konrad Busche GmbH & Co. KG except for internal use.

Contravention results in liability for damages. Further claims remain reserved.

1.4 Guarantee terms

The Terms and Conditions of Guarantee are contained in the General Terms and
Conditions of Trade of Konrad Busche GmbH & Co. KG.

1.5 Service / Customer service

Our Customer Service department is at your disposal for any technical queries
you may have.
Phone: +49 (0) 711 7 80 67-0
In addition, our employees are consistently interested in new information and
experiences resulting from the application that may be of value in improving our
products.

6 Konrad Busche GmbH & Co. KG

2 Safety

WARNING
Failure to observe the safety information below may have serious
consequences:
– Risk to persons due to electrical, mechanical or chemical effects
– Failure of important machine functions
– Environmental damage due to leaking hazardous substances
Read the safety and hazard information in this section thoroughly before
putting the machine into operation.
In addition to the information specified in this operating manual, always
comply with general safety and accident prevention regulations.
In addition to the information specified in this operating manual, the plant
operator/machine operator must comply with national occupational,
health, and safety regulations. It is also important to follow internal rules
and regulations.

Programmable industrial sewing machine 7

 2 Safety

2.1 Intended use

The safety of the machine is only ensured if it is used as intended.
The machine is intended solely for the programmable sewing of materials in the textile
industry.

The machine is not intended for use other than as described here; other use counts as
inappropriate. The following is prohibited in particular:

– processing of other materials,

– using the machine in potentially explosive areas.

Intended use also includes:

– Heeding all information from the operating manual

– Complying with the inspection and maintenance intervals

– Using operating supplies in accordance with applicable safety regulations

– Complying with the operating conditions.

The technical specifications mentioned in the technical data must be complied with
without exception.

Only use the machine as intended; otherwise there is no guarantee of safe and
reliable operation.
It is not the manufacturer but the plant operator who is responsible for any and
all personal injuries and material damage resulting from unintended use.

8 Konrad Busche GmbH & Co. KG

2.1 Intended use

2.1.1 Structural alterations to the machine

Construction and manufacturer's acceptance are based on the German Product Safety
Act (ProdSG). The machine is not allowed to be converted or otherwise altered without
prior written permission from Konrad Busche GmbH & Co. KG.

Any breach of this causes the machine to lose its EC conformity. Such a breach absolves
the manufacturer of the machine from warranty.

Any parts not in a perfect state must be replaced immediately.

Use original spare/wearing/accessory parts only. These parts have been specifically
designed for the machine. For parts from other sources there is no guarantee that they
have been designed and manufactured in line with load and safety requirements.

Parts and special features not delivered by Konrad Busche GmbH & Co. KG have not
been released for use with the machine.

2.1.2 Foreseeable misuse

Any use exceeding the concept of intended use and/or other use of the machine can
lead to severe injuries.
– Only use the machine for its intended purpose.

Programmable industrial sewing machine 9

 2 Safety

2.2 Personnel requirements

The machine is only allowed to be operated, maintained and repaired by persons who
have been qualified and/or trained for this. These persons must know the operating
manual and act in accordance with it. The respective authorisations for personnel must
be defined clearly.

Personnel require the following qualifications for the various activities:

Instructed personnel

Instructed personnel have been instructed by the plant operator or by qualified

personnel about their tasks and the potential risks of inappropriate behaviour.

Qualified personnel

Qualified personnel are able to do their work and recognise/avoid potential hazards on
their own as a result of their training, knowledge and experience and their familiarity
with regulations.

Electrical specialists

Electrical specialists are able to work on electrical equipment and recognise/avoid

potential hazards on their own as a result of their training, knowledge and experience
and their familiarity with standards and regulations.

Electrical specialists have been trained for their specific point of deployment and know
the relevant standards and regulations.

10 Konrad Busche GmbH & Co. KG

2.2 Personnel requirements

2.2.1 Responsibilities

Inappropriate handling can lead to severe personal injury and material damage.

All activities must therefore be carried out by qualified personnel only.

– Personnel must consist of individuals who can be expected to perform their work
reliably. Individuals whose response is impaired by drugs, alcohol, medication and
the like must not work on the machine.

– All persons working on the machine must read the operating manual and confirm
with their signature that they have understood it.

– Initially, personnel requiring training are only allowed to work on the machine under
the supervision of qualified personnel. The completion and success of instruction
must be confirmed in writing.

The plant operator is responsible for training and instructing personnel.

2.2.2 Obligations of personnel

Before working on or with the machine, all persons undertake the following:

– To comply with basic regulations concerning health, safety and accident prevention
– To read the safety information and warnings in this operating manual and to confirm
with their signature that they have understood the issues

2.2.3 Unauthorised persons

Unauthorised persons who do not have the required qualifications are not aware of the
hazards in the work area.
– Keep unauthorised persons away from the work area.

– Address persons in case of doubt and eject them from the work area if applicable.
– Interrupt work while any unauthorised persons are in the work area.

Programmable industrial sewing machine 11

 2 Safety

2.2.4 Instruction

The plant operator must instruct personnel at regular intervals. Keep a record of all
instructions given in order to keep track of matters.

Instruction given
Date Name Type of instruction Signature
by

2.3 General safety information

– Always read and understand the operating manual before operating and maintaining
the machine.

– Only use the machine for its intended purpose (see section "2.1 Intended use").

– Do not start the machine if other persons are in the danger zone.
– Refrain from any act which is likely to compromise the health and safety of people
and safe operation of the machine.

– Never operate the machine without the associated guards and safety devices. Never
take installed safety devices out of operation.

– Always keep the work area around the machine clean and tidy to prevent hazards
due to dirt and things lying around.
– Do not exceed the technical data (see section "3.3 Technical data").

– Keep all safety and hazard signs on the machine clean and renew them if necessary.

– Only qualified or trained personnel are allowed to operate or work on this machine
(see section "2.2 Personnel requirements").

– Take the machine out of operation immediately if a fault occurs. Have faults rectified
by appropriately trained specialists or by Konrad Busche GmbH & Co. KG.

– Always keep the operating manual at the machine's point of deployment. It must be
ensured that all personnel working on the machine can view the operating manual at
any time.

12 Konrad Busche GmbH & Co. KG

2.4 Safety measures for environment protection

2.4 Safety measures for environment protection

In all work obey the regulations for waste avoidance and proper waste
disposal/recycling.

In the course of installation, maintenance and decommissioning, in particular, it must be

ensured that materials that could jeopardise the groundwater – such as greases, oils,
coolants, solvent-containing cleaning fluids and the like – do not pollute the ground or
get into the drains. These materials must be caught, kept and transported in suitable
containers and disposed of in compliance with national regulations.

Programmable industrial sewing machine 13

 2 Safety

2.5 Special types of warning

2.5.1 Symbols used on the machine

Fatal injury hazard due to electricity

This symbol warns of a life-threatening electrical hazard.
Touching live parts poses a direct risk of death.

Warning of injuries to hands including crush injuries

This symbol warns of the danger of injuries to hands.
Hands can be crushed, dragged into the machine or be injured in other
ways.

Burn hazard due to hot surfaces

This symbol warns of a burn hazard due to hot surfaces.
Hot surfaces such as machine parts, containers and materials as well as hot
fluids are not always apparent.
Always wear protective clothing and safety gloves during all work in order
to avoid burns through hot surfaces.

Keep all safety and hazard signs on the machine in a legible state and renew
them if necessary.

2.5.2 Hazards due to electricity

DANGER
If live parts are touched there is danger of an electric shock.
– Keep electrical components closed the whole time.
– Only electricians who have been trained specially for work on electrical
equipment and can recognise and avoid hazards should be allowed to
work on the electrical equipment.
– Observe the (following) five safety rules:
1. Disconnect completely
2. Secure against reconnection
3. Verify that it is disconnected
4. Carry out grounding and short circuiting
5. Project against live parts

14 Konrad Busche GmbH & Co. KG

2.5 Special types of warning

DANGER
Electric shocks can lead to indirect accidents, e.g. falling from a height,
as a result of the person concerned being startled.
– Observe the five safety rules when working with electrical equipment.
– Only allow work with electrical equipment to be carried out by a
trained electrician.

– Before working on electrical equipment switch off the machine completely and
secure it against being switched on again.

– Only electrical specialists - e.g. plant electricians - are allowed to work on the
electrical equipment.
– Regularly check the electrical equipment for defects such as loose connections or
scorched cables. Have any defects rectified immediately.

– Have the electrical equipment and fixed electrical apparatuses tested by an electrical
specialist every 4 years at least.
Fixed electrical apparatuses are permanently installed apparatuses or apparatuses
that do not offer any carrying device and which, due to their weight, are difficult to
move. This also includes electrical equipment that is fitted on a temporary basis and
operated using movable device cabling.
– Have portable electrical equipment and extension and device cabling with plugs and
sockets tested by an electrical specialist, or by a trained person using suitable
inspection facilities, every 6 months at least.

Equipment is portable if, by its nature and in its normal use, it is moved while under
power. This includes, for example, electric floor cleaners.

– Alterations made after testing must comply with DIN EN 60204-1.

– Check the functioning of all the machine's safety devices regularly.

– Only use original fuses.

– Always keep the control cabinet doors locked.

– Damaged housings and leads must be repaired immediately or replaced before being
switched on.

Programmable industrial sewing machine 15

 2 Safety

2.5.3 Pneumatic power hazards

Air ejected under high pressure can penetrate the skin and cause serious injuries.

– Work on the pneumatic equipment must only be carried out by personnel with
specific knowledge of and experience with pneumatics. Before working on the
pneumatic equipment, switch it off and prevent unexpected restoration of power.

– Before starting repairs, depressurise the system sections that need to be opened and
the pressure pipes.

– Regularly inspect all pneumatic pipes, hoses and screw fittings for leaks and
externally recognisable damage.

– Carefully detach the hoses. The release of compressed air could whirl up dust and
swarf.

– Always hold pneumatic hoses away from your body.

– Protect unsealed air connections against soiling.

– Never interchange connections, plugs or switches. As this would otherwise lead to

malfunctioning.

16 Konrad Busche GmbH & Co. KG

2.5 Special types of warning

2.5.4 Laser hazard (when using an optional laser)

Optionally, lasers of either class 1 or 2 are used. These laser classes have low emission
levels. Eyes are protected from accidental, short-term exposure to the laser beam by the
lid-closing reflex.

Lasers of laser class 1 are labelled as follows:

LASER CLASS 1

Lasers of laser class 2 are labelled as follows:

LASER RADIATION
DO NOT STARE INTO BEAM
LASER CLASS 2

Lasers of laser class 3B are labelled as follows:

LASER RADIATION
DO NOT STARE INTO BEAM
LASER CLASS 3B

Lasers of laser class 3R are labelled as follows:

LASER RADIATION
AVOID DIRECT EYE EXPOSURE
LASER CLASS 3R

A label with the following information must be affixed at the laser aperture of class 3B
and 3R lasers:

LASER APERTURE
or

LASER RADIATION EMITTED FROM THIS APERTURE

or

AVOID DIRECT EXPOSURE TO BEAM –

LASER RADIATION APERTURE

– Avoid looking directly into the laser beam.

Programmable industrial sewing machine 17

 2 Safety

2.5.5 Sharp edge hazards

Contact with the optional edge cutting unit can cause finger and hand cuts.

– Keep fingers and hands clear of the optional edge cutting unit.

2.5.6 Hazards due to hot surfaces

Contact with hot parts can cause burns.

– Always wear protective clothing and safety gloves when working near hot parts. Parts
that can get hot are indicated by the "Warning of hot surface" symbol (see section
"2.5.1 Symbols used on the machine").

– Before maintenance and repair work, let all machine components cool down to the
ambient temperature.

2.5.7 Hazards due to incorrect spare parts

Incorrect or faulty spare parts may cause damage, malfunctioning or total failure, and
may also give rise to safety hazards.

– Use original spare parts only.

– Procure spare parts via Konrad Busche GmbH & Co. KG. The necessary details about
spare parts are given in the supplied bills of material or in the section "1.5 Service /
Customer service".

2.6 Personal protective equipment

During machine operation, always wear personal protective equipment, irrespective of
the risk assessment at work, to minimise health hazards.

– Always wear the personal protective equipment required for the respective task
when carrying out work.

– In the work area, obey all signs relating to personal protective equipment.

18 Konrad Busche GmbH & Co. KG

2.7 Safety devices and guards

The symbols have the following meaning:

Protective clothing
Protective clothing fits tightly all over without protruding parts and has
high tear resistance. It mainly provides protection against moving parts.
Do not wear rings, bracelets or other jewelry.

Safety shoes
Wear nonslip safety shoes to protect yourself against heavy falling parts
and prevent you from slipping.

Safety gloves
Wear safety gloves to protect your hands against friction, grazes,
punctures, deeper wounds, hot surfaces and chemical substances.

Safety goggles
Wear safety goggles to protect your eyes against media released under
high pressure or flying parts.

The personal protective equipment must be provided by the plant operator and must be
fit for purpose.
It is also necessary to obey national regulations, the guidelines of the risk assessment at
work and, if applicable, the operator's internal instructions.

2.7 Safety devices and guards

– Before switching the machine on, always make sure that all safety devices and guards
have been fitted properly and are functional.
– When subcomponents are delivered, the plant operator must ensure that the guards
are fitted according to the rules.
– During operation, never bridge or remove safety devices and guards or defeat them
in any other way.

– Guards are only allowed to be removed

after the machine has come to a standstill and
when unexpected restoration of power to the machine has been prevented.
– Check the functioning of all the machine's safety devices regularly.

Programmable industrial sewing machine 19

 2 Safety

2.8 Information for emergencies

Preventive measures
– Always be prepared for accidents or fires.

– Keep first aid equipment (first aid box, blankets etc.) and fire extinguishers at hand.

– Familiarise the personnel with accident reporting, first aid, fire-extinguishing and
rescue equipment.

– Keep access routes for rescue vehicles clear.

Measures in the event of accidents

– Trigger an emergency stop.

– Bring persons out of the danger zone.

– In the event of cardiac and/or respiratory arrest, administer first aid immediately.

– If anybody is injured, notify the first aid officer or the emergency medical service.

– Clear the access routes for rescue vehicles. If needed, detail somebody to marshal
the rescue forces.

– Extinguish any burning oil/grease with a CO2 or powder extinguisher.

– Use a CO2 extinguisher to put out any fire in the electric control system.

20 Konrad Busche GmbH & Co. KG

2.9 Obligations of the plant operator

2.9 Obligations of the plant operator

The machine is used in an industrial plant. The plant operator is therefore subject to the
legal requirements concerning health and safety at work.

In addition to the safety information in this operating manual, it is necessary to comply

with the safety, accident prevention and environmental protection regulations in force
where the machine is being used. The following applies in particular:

– The plant operator must ensure that the machine is only used as intended (see
section "2.1 Intended use").

– The plant operator must always keep the operating manual in a legible and complete
state at the machine's point of deployment.

– The plant operator must clearly define and arrange the responsibilities for
installation, commissioning, operation, maintenance, and cleaning.

– The plant operator must verify that no individual working on the machine is under
the minimum age stipulated by law.

– The plant operator must only let suitably qualified and trained personnel work on the
machine.
– The plant operator must ensure that all personnel working on or with the machine
have read and understood this operating manual.
The plant operator must also train the personnel and inform them about hazards at
regular intervals.

– The plant operator must provide personnel with personal protective equipment and
also ensure that this is used.
– The plant operator must make sure that individuals whose response is impaired by
drugs, alcohol, medication and the like do not work on the machine.

In addition, the plant operator is responsible for keeping the machine in a perfect
technical state so the following also applies:

– The plant operator must ensure compliance with the maintenance intervals
described in this operating manual.

– The plant operator must regularly check that all safety devices are functioning
correctly and are complete.

– The plant operator must regularly check that all safety and warning signs on the
machine are legible and stay on the machine.

Programmable industrial sewing machine 21

 2 Safety

22 Konrad Busche GmbH & Co. KG

3 Description of the machine

3.1 Overview

3.1.1 Overview of function elements

1 Sewing head 4 Feed dog

2 Take-up lever 5 Table top
3 Sewing needle 6 Lower part

Programmable industrial sewing machine 23

 3 Description of the machine

3.1.2 Overview of operator controls

1 Operator panel 2 Main switch

24 Konrad Busche GmbH & Co. KG

3.1 Overview

3.1.3 Overview of guards

1 Visual protection

3.1.4 Rating plate

The rating plate is located near the sewing

head.

Programmable industrial sewing machine 25

 3 Description of the machine

3.2 Function description

The machine is used for the programmable sewing of materials in the textile industry.
The machine consists of a sewing head and a lower part.

The user places materials, i.e. textiles, underneath the sewing needle. The feed dog
ensures the programmed advance rate.

The lower part makes sure the machine is standing safely and firmly.

3.3 Technical data

Please refer to the enclosed supplier documentation for detailed information.

3.3.1 Dimensions and weights of the lower parts

3.3.1.1 PV-ST100RO75
Width 1,000 mm
Height 800-950 mm
Weight 16.2 kg

3.3.1.1 GVU-80-2RO
Width 820 mm
Height 720 mm
Weight 12 kg

3.3.1.1 PZ100
Width 1,000 mm
Height 760 mm
Weight 15 kg

3.3.1.1 KB12-80
Width 800 mm
Height 750 mm
Weight 11.8 kg

26 Konrad Busche GmbH & Co. KG

3.3 Technical data

3.3.2 Connection data/performance

Voltage 230 V AC
Frequency 50/60 Hz
Pneumatic working pressure 6 bar

3.3.3 Material

Processing of materials such as metal, glass or wood is prohibited.

Always consult the manufacturer when using materials that deviate from the
ones listed below.

The following materials are suitable for processing:

– Textiles

– Plastic films

– Tarpaulin
– Packaging materials

– Fabrics made from plastic or rubber materials

– Fabrics coated with plastic or rubber

– Multilayer films made from plastic or rubber materials

3.3.4 Airborne noise emissions

A-weighted emission sound pressure level <70 dB(A)

3.3.5 Environmental conditions

Permissible ambient temperature in production +5 °C up to +35 °C

Permissible ambient temperature in storage +5 °C up to +40 °C
Permissible humidity 35-85 % relative humidity

Programmable industrial sewing machine 27

 3 Description of the machine

3.3.6 Features

Variants

The electrical connection has been designed as a two-pin grounded (Schuko) plug or CEE
plug.

Optionally, the presser foot is operated magnetically, mechanically or pneumatically.

Optionally, the thread cutter is operated magnetically or pneumatically.

Further options include:

- Lock (seam)

- Thread wiper
- Thread cutter

- Sewing foot ventilation

- Edge cutting unit

- Visual protection

- Laser

Delivery state

Delivery takes place on a euro pallet or on the machine frame.

28 Konrad Busche GmbH & Co. KG

4 Transport and storage
The machine is delivered to the customer by Konrad Busche GmbH & Co. KG or by an
authorised transport company.

4.1 Inspection by the recipient on handover

When the machine arrives at the customer's plant it must be inspected for visible
damage in transit.

– Immediately report any damage in transit to the transporting organisation.

4.2 Information about transport hazards

WARNING
The following specific hazards may arise during transport of the
machine/component:
– Suspended loads can fall, threatening life.
– If other lifting equipment is used than that specified here, serious
injuries can ensue.
– Protruding edges can lead to crush injuries or cutting wounds.

– Also read chapter "2 Safety".

– The machine or components are only allowed to be transported by suitably qualified
and instructed personnel (certified forklift operators) in compliance with all safety
information.

– When choosing suitable lifting equipment and load handling attachments, always
take the weight of the heaviest component into consideration (for weights, see
section "3.3 Technical data").

– Wear protective clothing, safety shoes, safety gloves and a helmet during the work.

– Always have the transport route on site secured by an additional person.

– Make sure that nobody is in the transport route or beneath suspended loads.

– Do not use pipes or add-on parts as attachment points.

– Always lift the machine slowly and carefully to ensure stability and safety.

Programmable industrial sewing machine 29

 4 Transport and storage

4.3 Intermediate storage

If the machine is not installed directly after delivery, it must be stored carefully in a
protected location. The machine must be stored in such a way that it is protected from
low temperatures, moisture, contamination from dirt and mechanical influences.

Please find the recommended storage conditions for the machine in the section "3.3.5
Environmental conditions".

No liability will be accepted for damage arising in the event of incorrect storage.

30 Konrad Busche GmbH & Co. KG

5 Installation

5.1 Information about installation hazards

WARNING
Trip hazard due to inappropriately laid power supply lines
 Lay all lines in such a way that they cannot be tripped over and do not
cause an obstruction.
 Colour highlight any tripping points that are unavoidable.

5.2 Preparations
Prior to installing the machine, make sure

– the connections for the voltage supply and compressed air supply have been
prepared

– the floor at the installation site has been cleaned.

5.3 Choice of installation site

5.3.1 Necessary operating and maintenance space

When choosing the installation site, observe the ambient conditions (see section
3.3.5).
When choosing the installation site, make sure there is enough operating and
maintenance space.
The space at the machine should not be less than the dimensions given in the
illustration below.

Programmable industrial sewing machine 31

 5 Installation

5.3.2 Floor requirements

WARNING
Loss of stability
A loss of stability may result in a significant danger of injury.
– The floor must be level.

5.4 Connecting the power supply

5.4.1 Power supply

WARNING
Danger of injury due to unexpected machine start-up
The machine can start up unexpectedly when connecting the voltage
supply.
 Before connecting the voltage supply, make sure that the main switch is
in position [O].

 Insert the plug of the supply line into a customer provided socket that is protected by
a 16 A fuse.

5.4.2 Connecting the compressed air supply

 Connect the compressed air supply (1) to the

maintenance unit (2).

32 Konrad Busche GmbH & Co. KG

6 Commissioning

6.1 Safety measures to be taken before commissioning

Familiarise yourself with the machine's
– operator and system controls,

– features,

– working principle,

– immediate environment,

– safety devices

– and the measures for an emergency.

Carry out the following activities before initial commissioning or recommissioning the
system:

– Check and make sure that all safety devices are attached and are working.

– Inspect the machine for visible damage; rectify any detected defects immediately or
notify them to the supervisory staff – the machine must only be operated in a perfect
state.

– Check and make sure that installation has been carried out correctly (completeness,
etc.).

– Check and make sure that only authorised persons are in the machine's work area
and that no other person is endangered by starting up the machine.

– Remove all objects and other materials from the machine's work area that are not
needed for its operation.

Programmable industrial sewing machine 33

 6 Commissioning

6.2 Setting up the height adjustment (optional)

6.2.1 Mechanical height adjustment

CAUTION
There is a danger of injury due to stored energy in the spring. The table
top can shoot upwards if the sewing head is removed.
 Only release the locking lever when adjusting the height.
 Only release the locking lever when the sewing head is installed.

 Release the locking lever (see arrow).

 Adjust the table top to the desired height.

 Retighten the locking lever.

6.2.2 Electrical height adjustment

 Press the button (1) to adjust the height of

the table top upwards.
 Press the button (2) to adjust the height of
the table top downwards.

34 Konrad Busche GmbH & Co. KG

7 Operation
Please refer to the enclosed supplier documentation for detailed instructions for
action.

7.1 Safety measures during normal operation

WARNING
Eye injury if a sewing needle breaks
There is a risk of eye injury if a sewing needle breaks.
 Never remove the optional visual protection.
 Wear safety goggles if no visual protection is available.

CAUTION
Slip hazard due to lubricating oil
There is a slip hazard if the lubricating system is defective.
 Pay attention to leaked liquids.
 Remove any lubricating oil spills immediately.

CAUTION
Crush hazard due to take-up lever movement
There is a crush hazard due to take-up lever movement.
 Do not reach into the take-up lever.

CAUTION
Puncture hazard due to sewing needle movement
There is a puncture hazard due to sewing needle movement.
 Do not reach into the sewing needle.
 Have all work at the machine carried out by instructed personnel only.

Programmable industrial sewing machine 35

 7 Operation

– Safety devices must not be removed or disabled while the machine is in operation.

– Operating personnel must ensure that no unauthorised persons are in the machine's
work area.

Carry out the following inspection activities every day:

– Inspect the machine for externally visible damage.

– Check that all safety devices are working.

36 Konrad Busche GmbH & Co. KG

7.2 Switching the machine on and off

7.2 Switching the machine on and off

 Switch the machine on (see arrow).

 Switch the machine off (see arrow).

Programmable industrial sewing machine 37

 7 Operation

7.3 Sewing operation

Please refer to the enclosed supplier documentation for detailed instructions for
action.

7.4 Changing the needle

Please refer to the enclosed supplier documentation for changing the needle.

7.5 Changing the thread

Please refer to the enclosed supplier documentation for changing the thread.

7.6 Changing the spool

Please refer to the enclosed supplier documentation for changing the spool.

38 Konrad Busche GmbH & Co. KG

8 Fault
Faults and remedial measures
We are not aware of any specific faults at this moment in time.

Fault Cause Remedy

Programmable industrial sewing machine 39

 8 Fault

40 Konrad Busche GmbH & Co. KG

9 Maintenance
Always observe the enclosed supplier documentation.

9.1 Safety measures when carrying out maintenance

Carry out the prescribed maintenance work like cleaning, lubrication, maintenance and
inspection according to the prescribed intervals.

Heed the following points before doing maintenance work:

– Using the main switch, switch off the central power supply. Disconnect the mains
plug.
– Depressurise the machine.
– Ensure that all machine parts have cooled down to the ambient temperature.

– Ensure that appropriate hoists and other lifting equipment are available for replacing
large machine parts.

– Make sure you do not bend your back when working on parts fitted at a low level;
always crouch. Make sure you are standing upright and your back is straight when
working on parts fitted at a high level.
– Replace any imperfect machine parts immediately.
– Use original spare parts only.
– Make sure that suitable collecting containers are available for all materials that could
jeopardise the groundwater (oils, cleaning agents and the like).

Carry out the following activities after maintenance and before starting up the machine:

– Check that all previously released screw connections have been retightened properly.

– Make sure that all previously removed safety devices, guards etc. have been refitted.

– Make sure that all tools, materials and other equipment have been removed from
the work area.

– Clean up the work area. Remove any leaked liquids and similar substances.

– Make sure that all the machine's safety devices are functioning correctly.

Programmable industrial sewing machine 41

 9 Maintenance

9.2 Inspection and maintenance work

9.2.1 Maintenance intervals

See
Maintenance point Maintenance work
section

Every day

Complete machine Visual inspection and cleaning 9.2.3.1

Annually

Complete machine Check screw fitting 9.2.4.1

Pneumatic components Check; replace if necessary 9.2.4.2

Special maintenance intervals

Pneumatic hoses (every 10 years at

Replace 9.2.5.1
the latest)

Lubricating oil Replace 9.2.5.2

Edge cutting unit (optional) Replace the blade 9.2.5.3

42 Konrad Busche GmbH & Co. KG

9.2 Inspection and maintenance work

9.2.2 Preparations

DANGER
Fatal injury hazard due to electric shock
Touching live parts may result in a fatal electric shock.
 Switch off the power supply to the machine before carrying out
maintenance and inspection work on the machine.

WARNING
Injury hazard due to escaping compressed air
As a result of leaks when dismantling pneumatic components under
pressure there is a danger of injury from escaping compressed air and a
resuspension in the air of for example dust particles or swarf.
 Before commencing work depressurise the pneumatic system.

WARNING
Injury hazard due to unexpected movements
There are numerous injury hazards due to the movements of the sewing
head or the lower part.
 All maintenance work must therefore be carried out by qualified
personnel only.

 Depressurise the pneumatic system.

 Switch the machine off (see chapter "7 Operation“).

 Prevent unexpected reconnection of the machine by disconnecting the mains plug.

9.2.3 Maintenance – daily operations

9.2.3.1 Visual inspection and cleaning

 Inspect the machine for

– Mechanical damage

– Damaged seals

– deposits of dirt and

– unusual noises.

• Report any damage to your supervisor immediately.

Programmable industrial sewing machine 43

 9 Maintenance

 Remove any dust and fibre residue from the machine.

The illustration resembles the version that is delivered.

The lubricating oil level must be between the top and the bottom mark.

 Check the lubricating oil level using the sight

glass (1).

9.2.4 Maintenance – annual

9.2.4.1 Inspect the screw fittings

 Check that all screw fittings of the machine are firmly in place.

 Tighten any loose screw fitting (at torques in line with the screw size and strength
class).

9.2.4.2 Pneumatic components

 Carry out the preparations (see section "9.2.2 Preparations").

WARNING
Danger of injury arising from escaping compressed air and atmospheric
resuspensions
When replacing pneumatic components unforeseen residual pressure in
the system can lead to injuries of the eyes and skin resulting from
escaping compressed air and a resuspension in the air of for example dust
particles or swarf.
 Wear at work protective goggles, protective gloves and protective
clothing.
 Disconnect carefully the pneumatic hoses.
 Never point pneumatic hoses at other people.

 Check all pneumatic leads and connections for leaks and damage.

 Replace all damaged pneumatic components.

44 Konrad Busche GmbH & Co. KG

9.2 Inspection and maintenance work

9.2.5 Special maintenance intervals

9.2.5.1 Pneumatic hoses (every 10 years at the latest)

 Carry out the preparations (see section "9.2.2 Preparations").

WARNING
Danger of injury arising from escaping compressed air and atmospheric
resuspensions
When replacing pneumatic components unforeseen residual pressure in
the system can lead to injuries of the eyes and skin resulting from
escaping compressed air and a resuspension in the air of for example dust
particles or swarf.
 Wear at work protective goggles, protective gloves and protective
clothing.
 Disconnect carefully the pneumatic hoses.
 Never point pneumatic hoses at other people.

 Replace the pneumatic hoses at the latest after 10 years. This can be ascertained
according to the manufacturing date of the hoses (printed on each hose).

9.2.5.2 Replacing the lubricating oil

WARNING
Crush hazard when tilting the sewing head
Fingers and hands may be crushed when tilting the sewing head.
– The machine must be standing on an even surface.
 All maintenance work must therefore be carried out by qualified
personnel only.
 Always tilt the sewing head right up to the stop.

CAUTION
Danger of skin irritations
Skin irritations may occur when coming into contact with oil.
 Always wear safety gloves.

Please refer to the enclosed supplier documentation for replacing the lubricating
oil and the replacement intervals.

Programmable industrial sewing machine 45

 9 Maintenance

9.2.5.3 Edge cutting unit (optional)

WARNING
Injury hazard due to sharp edges
Contact with the optional edge cutting unit can cause finger and hand
cuts.
 Switch off the power supply to the machine.
 All maintenance work must therefore be carried out by qualified
personnel only.

Please refer to the enclosed supplier documentation for replacing the blades.

46 Konrad Busche GmbH & Co. KG

10 Decommissioning and dismantling

DANGER
Fatal injury hazard due to electric shock
Touching live parts may result in a fatal electric shock.
 Switch off the power supply to the machine prior to decommissioning
and dismantling.

WARNING
Injury hazard due to mechanical hazards
There are injury hazards such as scratches, punctures or bruises.
 Disconnect all power supply lines.
 Collect liquids (lubricating oil) and dispose of them in accordance with
valid local regulations.
 Wear protective clothing, safety gloves and safety shoes.

 Switch the machine off (see chapter "7 Operation“).

 Prevent unexpected reconnection of the machine, e.g. by padlocking the main

switch.

10.1 Disposal
– Dispose of the line in an environmentally friendly manner, separating
the various materials.
– Dispose of liquids in conformity with valid regulations or, if necessary,
contact Konrad Busche GmbH & Co. KG.

Programmable industrial sewing machine 47

 11 Annex

11 Annex

11.1 EC Declaration of conformity

The EC Declaration of conformity for this machine is shown on a separate document
and is attached to this operating manual.

48 Konrad Busche GmbH & Co. KG

11.2 Documents in the annex
The following documents can be found in the annex of this operating manual:
– Operating manuals

– EC Declaration of conformity

Programmable industrial sewing machine 49