Adler 806 Service Manual

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Part 3: Service Instructions class. 806

1.

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5

2.Machine head (Class 806-111)

2.1	Stitch regulator and transmission lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	6
2.1.1	0-position of the stitch regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	6
2.1.2	Position of the transmission lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	7
2.2	Rocker and throat plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	9
2.2.1	General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	9
2.2.2	Position of the rocker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	9
2.2.3	Timing the rocker oscillation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	10
2.2.4	Range of the rocker oscillation (throw width) . . . . . . . . . . . . . . . . . . . . . . . . . . .	11
2.2.5	Horizontal position of the throat plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	12
2.2.6	Height of the throat plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	13
2.3	Adjusting the bobbin winder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	14
2.4	Hook, needle bar, hook guard and needle guide . . . . . . . . . . . . . . . . . . . . . . . . .	15
2.4.1	Loop stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	15
2.4.2	Sliding clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	16
2.4.3	Needle bar height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	17
2.4.4	Distance between the hook and the needle . . . . . . . . . . . . . . . . . . . . . . . . . . . .	18
2.4.5	Position of the needle guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	19
2.5	Bobbin case lifter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	20
2.5.1	General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	20
2.5.2	Amount of the finger travel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	20
2.5.3	Amount of the lifting gap (position of the finger travel) . . . . . . . . . . . . . . . . . . . . . .	21
2.5.4	Timing the bobbin case lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	22
2.6	Sewing foot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	23
2.6.1	General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	23
2.6.2	Timing the sewing foot movement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	23
2.7	Thread take-up spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	24
2.8	Lifting the thread tensioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	25
2.9	Thread advancing device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	26
2.10	Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	27
2.10.1	General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	27
2.10.2	Mode of function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	28
2.10.3	Checking oil level and oil supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	28
2.10.4	Adjusting the hook lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	29
2.10.5	Oil change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	30
2.10.6	Topping-up oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	30
2.11	Sewing arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	31
2.11.1	General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	31
2.11.2	Lower position of the arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	31
2.11.3	Speed "Sewing arm up and down " . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	31
2.11.4	Damping the cylinder in its end position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	32

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2.12	Thread cutter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .						33
2.12.1	Sequence of functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .						33
2.12.2	Lateral position of the thread pulling knife . . . . . . . . . . . . . . . . . . . . . . . . . . . .						34
2.12.3	Height of the thread pulling knife . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .						35
2.12.4	Position of the counter-knife in respect to the thread pulling knife . . . . . . . . . . . . . . .						36
2.12.5	Position of the hook thread clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .						37
2.12.6	Position of the control cam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .						38
2.12.7	Swivelling range of the thread pulling knife . . . . . . . . . . . . . . . . . . . . . . . . . . .						38
2.12.8	Position of the roller lever in respect to the control cam . . . . . . . . . . . . . . . . . . . .						39
2.12.9	1st and 2nd position of the thread cutter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .						40

3.Machine head (Class 806-121)

3.1	Adjustment aids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	41
3.1.1	Gauge set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	41
3.1.2	Description and adjustment of the integrated adjustment disk . . . . . . . . . . . . . . . . .	42
3.1.3	Position of the integrated adjustment disk in respect to the arm shaft . . . . . . . . . . . . .	43
3.2	Sewing foot height / lower stroke position . . . . . . . . . . . . . . . . . . . . . . . . . . . .	44
3.3	Needle thread tension release . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	45
3.4	Thread tensioning spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	46
3.5	Bobbin winder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	47
3.5.1	Adjusting the bobbin winder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	47
3.5.2	Cylindrical winding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	47
3.5.3	Replacing friction ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	48
3.5.4	Resetting bobbin winder wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	48

3.6Hook adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

3.6.1	Loop stroke and distance between the hook and the needle . . . . . . . . . . . . . . . . . .	49
3.6.2	Hook drive housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	50
3.6.3	Bobbin case support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	51
3.6.4	Adjusting the throat plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	52
3.6.5	Adjusting the hook guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	53
3.7	Thread cutter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	54
3.7.1	Control cam for timing the knife movement . . . . . . . . . . . . . . . . . . . . . . . . . . . .	54
3.7.2	Position of the stationary knife . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	55
3.7.3	Regrinding the stationary knife . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	56
3.7.4	Adjustment sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	57
3.7.5	Hook-knife . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	58
3.7.6	Cutting pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	59
3.8	Replacing right hand arm shaft bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	60
3.9	Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	61
3.9.1	General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	61
3.9.2	Checking oil level and oil supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	62
3.9.3	Hook lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	64
3.10	Adjusting the remaining thread monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	65
3.11	Sewing arm position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	66
3.11.1	Lower position of the arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	66
3.11.2	Speed of the sewing arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	66
3.11.3	Damping the cylinder in its end position . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	67

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4.Folding device

4.1	Outer frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	68
4.1.1	General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	68
4.1.2	"Folding position" of the outer frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	68
4.1.3	Timing the action of the switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	69
4.1.4	Damping the cylinder in its end position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	70
4.2	Inner frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	71
4.2.1	General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	71
4.2.2	Adjustment range of the front setting wheel . . . . . . . . . . . . . . . . . . . . . . . . . . .	71
4.3	Middle slide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	72
4.3.1	General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	72
4.3.2	Adjustment range of the rear setting wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . .	73
4.3.3	Limiting the movement" Middle slide up " . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	74
4.3.4	"Adjustment position" of the middle slide . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	75
4.3.5	Speed "Middle slide forwards, down, up " . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	76
4.3.6	Timing the operation of the switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	77
4.4	Lateral slide, front slide and corner slide . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	78
4.4.1	General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	78
4.4.2	Front position of the slide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	78
4.5	Corner slide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	79
4.5.1	Position of the "Folding edge" of the lateral slide . . . . . . . . . . . . . . . . . . . . . . . . .	79
4.5.2	General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	80
4.5.3	Position of the entered corner introduction slide . . . . . . . . . . . . . . . . . . . . . . . . .	80
4.5.4	Height of the corner introduction slide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	81
4.6	Position of the two setting wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	82

5.Stacker

5.1	General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	83
5.2	Turning the rest of the stacker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	84
5.3	Lateral position of the roller-out and of the stacker . . . . . . . . . . . . . . . . . . . . . . . .	85
5.3.1	Lateral position of the roller-out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	85
5.3.2	Lateral position of the stacker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	85
5.4	Position of the opened inner shackle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	86
5.5	Position of the opened outer shackle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	86
5.6	Sensitivity of the light barrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	87
5.7	Lower position of the rollers of the roller-out . . . . . . . . . . . . . . . . . . . . . . . . . . .	87
5.8	Speed of the outer shackle, of the inner shackle and of the deposit rest . . . . . . . . . . . .	88
5.9	Speed of "Ejection rollers up and down " . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	89
5.10	Intensity of the air current and blowing direction of the nozzle . . . . . . . . . . . . . . . . .	89

6.Adjustment options

6.1	Selecting the machine class . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	90
6.2	Remaining thread monitor (only 806-121) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	90
6.3	Continuous operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	91
6.4	End bearing switch of the transfer carriage available . . . . . . . . . . . . . . . . . . . . . .	91
6.5	Measuring the end positions of the transfer carriage . . . . . . . . . . . . . . . . . . . . . . .	91
6.6	Checking the roll-out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	92
6.7	Checking the sewing motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	92

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7.Transfer carriages

7.1	General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	93
7.2	Adjusting the parallelism of the transfer plate . . . . . . . . . . . . . . . . . . . . . . . . . .	93
7.3	Setting the reference point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	94
7.4	Setting the limit switches S45 and S59 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	95
7.4.1	X-axis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	95
7.4.2	Y-axis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	96
7.5	Position balance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	97
7.5.1	General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	97
7.5.2	Balancing the positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	98
8.	Multitest System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	100
8.1	Displaying the programme version and the check sum . . . . . . . . . . . . . . . . . . . . .	100
8.2	Testing the working memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	101
8.3	Displaying the DIP switch setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	101
8.4	Selecting input elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	101
8.5	Checking input elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	102
8.6	Selecting output elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	103
8.7	Checking stepping motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	104
8.8	Checking sewing motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	104
8.9	Displaying error messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	104
9.	Terminal self-test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	105

10.Start messages

10.1	Start screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	107
10.2	"MP GP" message . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	107

11.Control error messages

11.1	Control error message . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	108
11.2	Machine programme error messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	108

12.Pneumatic conditioning unit

12.1Air filter and water separator

12.2Pressure relief valve . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	112
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	112

13.Monthly maintenance

13.1	Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	113
13.2	Ventilation grid of the control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	114
14.	Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	115

1.General

The present Service Manual describes the sequence to be respected when adjusting the sewing unit.

ATTENTION !

The different adjustment positions are interdependent.

Therefore, all adjustments must be made in the described sequence.

ATTENTION !

The actions described in the present Manual must be carried out exclusively by specialists or by the properly qualified persons!

Danger of breakage !

Before restarting the machine that has been dismounted, first carry out all the necessary adjustments.

Caution: Danger of bodily injuries !

Before proceeding to repairs, transformations and maintenance:

–Press the key "O", so that the machine stops in the position "Safe motor stop ".

Adjustments and functions tests during the operation of the sewing unit

–When carrying out the adjustments and testing the functions during the operation of the machine, note all safety measures and proceed with the utmost care.

Adjustments in the needle area

–For avoiding injuries, remove the respective parts before proceeding to the adjustments.

With the exception:

of the parts that are required for the adjustment.

5

2.Machine head (Class 806-111)

2.1Stitch regulator and transmission lever

2.1.10-position of the stitch regulator

1

2

Caution: Danger of bodily injuries !

The machine must be in the position "Safe motor stop " .

Rule and control

The needle bar should not ”oscillate” when sewing without zigzag function.

–Lower the sewing head by the function "Lifting/lowering the sewing head ".

–Press the key "O".

"Safe motor stop” will be switched on.

–Unscrew oil pan cover.

–Introduce hexagon screw screwdriver into the screw 1.

–Turn the setting wheel of the stitch regulator until the spanner moves as little as possible..

3

Correction

–Loosen counter nut 3.

–Turn screw 2 accordingly.

–Tighten counter-nut 3.

6

2.1.2Position of the transmission lever

The lever 2 transmits the motion of the feed shaft 3 to the rocker 1.

Caution: Danger of bodily injuries !

The machine must be in the position "Safe motor stop".

Rule and control

The lever 2 should be in vertical position when the zigzag function is snot activated.

Correction

–Lower the sewing head by the function "Lifting/lowering the sewing head ".

–Press the key "O".

"Safe motor stop " will be switched on.

–Loosen screw 4.

–Turn the lever on the shaft accordingly.

–Tighten screw 4.

Note

In case of a wrong adjustment, the ”oscillations” of the needle bar and 1 of the throat plate will not be synchronous during the zigzag operation.

2

3

4

7

1

2

3

4

5

6

7

8

9

10 11 12 13

14 15

16

17

18

19

8

2.2Rocker and throat plate

2.2.1General information

While the needle bar and the throat plate are performing a complete oscillation movement during the zigzag function, the needle bar will move 2 times up and down.. This is ensured by the couple of gears 1 and 2, having a transmission ratio of 1 : 2..

2.2.2Position of the rocker

Caution: Danger of bodily injuries !

The machine must be in the position "Safe motor stop ".

Rule and control

The needle should stitch into the centre of the 2 mm bore-hole of the gauge 3 (part no. 0804 400270) when the machine is out of the zigzag mode.

Correction in X direction

–Lower the sewing machine by the function "Lifting/lowering the sewing machine".

–Press the key "O".

"Safe motor stop " will be switched on.

–Loosen the screws 4 on the two setting blocks 5.

–Loosen the clamping screw 7 on the drive level 6.

–Loosen the screws 8 and 12 on the bearing for the thread take-up lever guide 5.

–Loosen the clamping screws 17 and 18 on the arm shaft crank 19.

–Loosen slightly the position screw 16 on the arm shaft crank.

–Proceed to a correction.

If required, shift the sewing foot stroke shaft 10 in the axial direction after having loosened following screws:

The screws on the two setting rings 11 and 13, the screw 14 on the block 15.

–Retighten all the previously loosened screw and note the following: Axial fixing of the rocker,

horizontal position of the setting block 5 , correct position of the wicks,

minimum possible play of the thread take-up lever guide 9.

Correction in Y direction

–Lower the sewing head by the function "Lifting/lowering the sewing head ".

–Press the key "O".

"Safe motor stop " will be switched on.

–Loosen the clamping screw 7 on the drive lever 6.

–Change the rocker position accordingly.

–Retighten the clamping screw.

Note

Following a correction in X-direction, check and, if required, correct the distance between the hook and the needle.

9

2.2.3Timing the rocker oscillation

1

2

3

Caution: Danger of bodily injuries !

Do not introduce your hands into the moving machine parts.

Rule and control

–In the zigzag mode, when stitching into the upper bartack point, the needle should be ”driven inwards to the same extent as it is driven when stitching into the lower.

–Both bartacking stitches should be equidistant top the "zero stitch”.

–Lower the sewing head by the function "Lifting/lowering the sewing head ".

–Press the key "O".

"Safe motor start " will be switched on.

–Place a piece of paper onto the fabric rest and hold it there.

–Turn the setting wheel 1 for determining the position of the "zero stitch".

–Select the "zigzag" function.

–Turn the setting wheel 1.

Correction

–Loosen screw 2.

–Turn the gear 3 on the hook driving shaft 3 accordingly.

–Retighten the screws 3.

ATTENTION !

A wrong setting can cause needle breakage.

10

2.2.4Range of the rocker oscillation (throw width)

1

Caution: Danger of bodily injuries !

The machine must be in the position "Safe motor stop ".

Rule and control

In the zigzag mode of the machine, the "upper" and the "lower" stitches on a piece of paper should have a distance of 5 mm.

In a set pocket, this will result in a throw width of about 3 mm, depending on the type of fabric and thread and on the thread tension.

–Lower the sewing head by the function "Lifting/lowering the sewing head".

–Press the key "O".

"Safe motor stop " will be switched on.

–Select the "zigzag " function.

–Place a piece of fabric onto the fabric rest and hold it there.

–Turn the handwheel.

Correction

–Turn the counter-nut 1 and the stop screw 1 accordingly.

2

11

2.2.5Horizontal position of the throat plate

1

2

3

4

5

Caution: Danger of bodily injuries !

The machine must be in the position "Safe motor stop ".

Rule and control

–In X-direction:

In the loop formation position – or a bit later – the needle shank 2 should be distanced 0.3 mm from the right side of the stitch hole 1.

–In Y-direction:

In this direction, the needle should stitch in the middle of the stitch hole.

Correction

–Lower the sewing head by the function "Lifting/lowering the sewing head ".

–Press the key "O".

"Safe motor stop " will be switched on.

–Loosen the screws in the bore-hole 3 and 5 and change the position of the throat plate 4 accordingly.

–Retighten the screws in the bore-holes 3 and 5.

12

2.2.6Height of the throat plate

1 2

Caution: Danger of bodily injuries !

The machine must be in the position "Safe motor stop ".

Rule and control

The stitch hole mushroom button must stand 0,5 mm under the top of the fabric rest.

Correction

–Lower the sewing head by the function ”Lifting/lowering the sewing head".

–Press the key "O".

"Safe motor stop " will be switched on.

–Loosen screw 1.

–Turn the block 2 accordingly.

–Retighten the screw 1.

13

2.3 Adjusting the bobbin winder

B

A

1 2

3 4

Rule and control

The bobbin winder should stop automatically when the bobbin when the thread wound on the bobbin is about 0,5 mm from its rim.

The thread should be wound cylindrically.

Caution: Danger of bodily injuries !

The machine must be in the position "Safe motor stop ".

Correction

1. Small changes in the filling amount

–Regulate the bobbin winder flap 1 by the screw 2.

2. Major changes in the filling amount

–Remove arm cover.

–Loosen screw 4.

–Turn tripping cam 3.

In A arrow direction: for small filling amount In B arrow direction for major filling amount

–Retighten screw 4.

–Replace arm cover.

14

2.4Hook, needle bar, hook guard and needle guide

2.4.1Loop stroke

1

2

3

4

The loop stroke is the distance covered by the needle bar from its lower dead centre up to the point where the point of the hook coincides with the middle of the needle.

The 1st screw on the hook – seen in the direction of rotation of the hook – is located on the flat side of the hook shaft.

Being fixed, the hook cannot rotate on the shaft during the sewing process. If the hook is jammed, the sliding clutch will react.

Caution: Danger of bodily injuries !

The machine must be in the position "Safe motor stop".

Rule and control

–The adjustment of the rocker position must be correct.

–The loop stroke should amount to 2 mm when the machine in not in the zigzag mode.

–Lower the sewing head by the function "Lifting/lowering the sewing head ".

–Press the key "O".

"Safe motor stop " will be switched on.

–By means of the block 2 (part no.. 0981 150002) press the gauge 1 (Part no. 0981 150003) against the rocker.

–Retighten the screw 3 on the block 2.

–Remove the gauge 1.

5 6 – Turn the setting wheel in the arrow direction until the block 2 is in contact with the rocker.

In this position, the hook point should coincide with the middle of the needle.

Correction

	–	Loosen the clamping screw in the bore-hole 4 by a hexagon screw
		screwdriver (spanner opening 5 mm).
		The screw 5 is located on the setting ring 6.
	–	Turn the hook on the driving shaft until the tip of the hook stands
0,5		against the middle of the needle.
	–	Ensure that the air gap in the jaw clutch amounts to 0.5 mm.
		Retighten the clamping screw 5 in the bore-hole 4.

15

2.4.2Sliding clutch

1

2

3

4

Caution: Danger of bodily injuries !

The machine must be in the position "Safe motor stop ".

Rule and control

The sliding clutch should react when the hook is jammed.

Adjust the sliding clutch 3 so that it reacts at a torque of 4 Nm.

Correction

–If the clutch reacts too often, turn-in the two screws (spanner opening 3 mm) at the on the face of the sliding clutch 3.

If the two screws are turned a quarter (1/4) of a revolution, the torque will e increased by about 10 %.

Re-engage the sliding clutch

Following a reaction of the sliding clutch, the latter must be re-engaged in the following manner::

–Introduce the hexagon screw driver into the screw of the bore-hole 4 and into the clamping screw 2.

–Turn the handwheel 6 until the clutch is re-engaged.

16

2.4.3Needle bar height

2 3

0,3

1

Caution: Danger of bodily injuries !

The machine must be in the position "Safe motor stop ".

Rule and control

In the loop formation position, the hook tip 3 should stand more or less under the middle of the furrow of the needle 2. When the machine is out of the zigzag mode.

–Lower the machine head by the function "Lifting/lowering the machine head ".

–Press the key "O".

"Safe motor stop " will be switched on.

Correction

–Loosen the two screws 1.

–Change the height of the needle in the way that the tip of the hook stands a bit (about 0,3 mm) under the middle of the furrow of the needle.

Do not turn the needle.

–Retighten the screws 1.

Note

Following a correction, check the position of the needle guide and of the hook guard.

17

2.4.4Distance between the hook and the needle

1

2

3

Caution: Danger of bodily injuries !

The machine must be in the position "Safe motor stop ".

The distance between the hook and the needle must be checked after inserting a needle that belongs to a different size group

(80-110 Nm or 120-140 Nm).

Rule and control

In the loop formation position, the distance between the hook and the furrow of the needle must amount to 0.1 mm when the machine is out of the zigzag mode.

–Lower the machine head by the function "Lifting/lowering the machine head".

–Press the key "O".

"Safe motor stop " will be switched on.

–Remove the stitch throat.

0,1

0,1

R 4

–Check the distance. The needle must not osculare needle guard 5.

Correction

–Move the machine in the loop formation position by turning the handwheel.

–Loosen the screws 1 and 3.

–Loosen the screws 7

–Remove the stitch throat.

–Loosen screws of bobbin case retainer 6 and take bobbin case retainer.

–Non loosen accessible screws (SW 1,5) of the hook guard 4 to be laterally displaced.

ATTENTION !

Do not loosen screws securing the vertical position.

–Displace hook guard 4 in the direction of R.

–Displace the hook case 2 sideways until the distance between the furrow of the needle and the hook tip amounts to 0.1 mm.

–Retighten the screws 1 and 3.

–Displace the hook guard backwardly until the conical tip of the needle contacts the hook guard, without deflecting the needle.

ATTENTION !

The hook guard 4 sheet should not touch the hook.

–Tighten scrwes (SW 1,5) of the hook guard.

–Reassemble bobin case retainer and throat plate.

18

2.4.5Position of the needle guide

2

	2
	3
1	4
	5
	5

The needle guide 5 should guide the needle during the sewing process in order to avoid its excessive deflection by the fabric. Otherwise, skipped stitches can occur.

The distance between the hook and the needle must be checked after inserting a needle that belongs to a different size group (80-110 Nm or. 120-140 Nm)

Caution: Danger of bodily injuries !

The machine must be in the position "Safe motor stop "

Rule and control

When the needle is in its lowest position, its distance to the needle guide should be as small as possible, but it should not touch the guide.

If the distance is too narrow, the needle may brake in the furrow area..

But if the distance is too wide, skipped stitches can occur, because the needle would be deflected by the fabric excessively.

–Lower the sewing head by the function "Lifting/lowering the sewing head".

–Press the key "O".

"Safe motor stop " will be switched on.

Correction

–Loosen the screws 4.

–Remove the throat plate 2.

Ensure that the positioning aids 1 are well fastened and cannot be displaced.

–Loosen the clamping screw 3.

–Change the position of the needle guide 5 accordingly.

–Tighten the clamping screw 3.

–Replace the throat plate 2.

Make sure that the positioning aids 1 are located in the bore-holes of the throat plate.

–Tighten the screws 4.

19

2.5Bobbin case lifter

2.5.1General information

1

2

3				4	5

The thread take-up lever should pass the thread between the bobbin case 4 and its support 3. For ensuring a free thread passage, the bobbin case must be lifted in this moment by the bobbin case lifter. This will ensure the desired seam pattern with the lowest possible thread tension.

Wrong adjustments may have following effects:

–Thread breakage

–Eyelets on the fabric underside

–High noise level

2.5.2Amount of the finger travel

Caution: Danger of bodily injuries !

The machine must be in the position "Safe motor stop ".

Rule and control

The support of the lever 5 should be eccentric. This will be ensured when the nut 2 is flush with the outer edge of the shaft.

–Lower the sewing head by the function "Lifting/lowering the sewing head".

–Press the key "O".

"Safe motor stop " will be switched on.

Correction

–Loosen the nut 2 by the special spanner 1and change the eccentricity accordingly.

–Tighten the nut 2.

Note

Following a correction, check the travel amount and the travel moment.

20

2.5.3Amount of the lifting gap (position of the finger travel)

1 2

Caution: Danger of bodily injuries !

The machine must be in the position "Safe motor stop ".

Rule and control

The X distance between the lifted bobbin case and its holder should correspond to the size of the thread used.

–Lower the sewing head by the function "Lifting/lowering the sewing head".

–Press the key "O".

"Safe motor stop " will be switched on.

Correction

–Loosen screw 1.

–Change the position of the finger 2 accordingly.

–Tighten the screw.

21

2.5.4Timing the bobbin case lifting

1

2

3

4

Caution: Danger of bodily injuries !

The machine must be in the position "Safe motor stop ".

Rule and control

The bobbin case must be in its lifted position when the thread passes between the bobbin case 3 and its support 4.

–Lower the sewing head by the function "Lifting/lowering the sewing head".

–Press the key "O".

"Safe motor stop " will be switched on.

–Turn the handwheel.

–Watch the thread passage.

Correction

–Loosen the two screws 1.

–Turn the handwheel until the hook tip, after picking up the loop, is in its ”3 o’clock ” position.

–Turn the shaft 2 by a hexagon screw spanner (spanner opening 2,5

mm)until the finger stands at the front inversion point, where the case is completely lifted.

–2 Tighten the screw 1.

22

2.6Sewing foot

2.6.1General information

The adjustment of the upper and lower sewing foot travel position is described under chapter 6.2.6 of the Operating Instructions.

2.6.2Timing the sewing foot movement

1 2

Caution: Danger of bodily injuries !

The machine must be in the position "Safe motor stop ".

Rule and control

The sewing foot should start moving upwards at the moment of the loop formation.

–Lower the sewing head by the function "Lifting/lowering the sewing head".

–Press the key "O".

"Safe motor stop " will be switched on.

Correction

–Loosen the two screws 1.

–Turn the eccentric 2 on the shaft accordingly.

–Tighten the screws 1.

23

2.7Thread take-up spring

1

2

Caution: Risk of Injury !

The machine must be in the position "Secured stop of motors".

Rule and control

Adjust the travel and the tension of the thread take-up spring in a way that at the moment when the spring reaches its lowest position, the eye of the stitching needle is disappearing in the fabric.

–Lower the sewing head by the function "Lifting/lowering the sewing head".

–Select the "speed" function.

–Enter the value 70 by the numerical keys and confirm by the

RETURN key.

–Press key "F2" for starting the sewing process.

–Watch the thread take-up spring.

–Press key "F3" for stopping the sewing machine head.

Correcting the travel

–Loosen slightly the screw 2 on the arm 1 by using a hexagonal screw spanner.

–By means of the bolt 1, turn the entire thread tension unit accordingly.

–Tighten screw 2.

Correcting the tension

		–	Press the key "O".
			"Safe motor stop " will be switched on.
		–	Loosen the screw 2 on the arm 1.
		–	Pull out the thread tension unit.
		–	Loosen the screw 4.
		–	Turn the bolt 3 accordingly.
		–	Tighten the screw 4.
		–	Replace the thread tension unit.
3	4	–	Tighten the screw 2.

24

2.8Lifting the thread tensioner

1

2

3

The thread tensioner will be lifted during the cutting process or after pressing the button 3 on the supporting plate.

Caution: Danger of bodily injuries !

Turn off the main switch.

Switch off the machine before adjusting the lifting of the thread tensioner.

Rule and control

The thread must pass freely through the lifted tensioner during the cutting process..

–By means of the traction rod 1, lift the thread tensioner as far as possible.

Correction

–Loosen the screw 1.

–Change the position of the traction rod 2 accordingly.

–Tighten the screw 1.

25

2.9Thread advancing device

1

2

During the cutting process, the thread advancing device 2 will be moved forwards after picking up the loop, and it will be returned during the 2nd movement phase of the thread cutting knife

The thread advancing device has been timed by the control unit. No change is possible.

The thread advancing device ensures a defined thread length required for starting the seam and it compensates for any thread elongation.

Caution: Danger of bodily injuries !

Turn off main switch.

Turn off the machine before adjusting the thread advancing device.

Rule and control

The thread advancing device 2 should advance enough thread to meet the following requirements for the next sewing cycle :

–Safe seam beginning.

–Pulling the thread end under the fabric.

–No "thread deflection" into the hook.

Correction

–Loosen the screw 1.

–Change the position of the thread advancing device 2 accordingly.

–Tighten the screw 1.

26

2.10	Lubrication
	1	2	3	4		5	6	7	8
					18	19	20	21
	17
	16
	15
			14	13	12		11	10	9

2.10.1 General information

–The wicks used for the lubrication of the respective elements in the machine head should not touch the re-circulation wick.

–The plastic cap on the hook impedes the suction of dust and fluff into the hook case by the vacuum pump.

–The oil splash screw 22 ensures that enough oil is supplied to the

22collecting sheet even if the oil level is very low..

–When completing the machine or following a longer machine stop, lubricate the ”dried up” wicks before restarting the machine, because an insufficient lubrication can cause damages.

–The slotted screw 24 under the lubrication adjustment screw 23

23can be turned out, so that any obstructions of the oil ducts in the hook race can be eliminated by a blowing gun.

24	Turn-in the screw 24 completely.

27

2.10.2 Mode of function
	Oil supply from the sump to the sewing head
	The oil passes from the oil sump to the cavity in the sewing head
	through the spiral grooves in the hook driving shaft 19 and through the
	duct 7. The check valve 9, contained in this duct, avoids the oil
	backflow when the machine is out of operation.. The oil supply through
	this duct can be controlled by the sight glass 5.
	Most of oil delivered by the brass tube 4 flows into the bore hole of the
	hollow shaft 3.. This hollow shaft contains a wick, that passes the oil to
	the lubrication points of the foot lifting mechanism and to the sump in
25	the sewing head.
	From here, the oil is conducted through the wicks to the articulations
	of the foot lifting mechanism and to the rocker. The foot lifting
	eccentric is lubricated by the wick 25, sucking the oil out of the cavity.

26 27	Oil supply from the machine head to the hook case
	The oil splashed in the sewing head is picked up by the felt, passing
	the oil to the lower wick, which in turn delivers the oil to the hook case.
	The oil dropping from the brass tube 4 into the cavity is collected by
35	the felt plate 1, passing then via the duct 20 to the hook case.

	Oil supply to the hook
34	The oil returned from the sewing head flows through the duct 32 into

28the hook case. Here, the oil can rise up to the level of the suction pipe 31.

29The hollow hook shaft 23 conveys the oil via the spiral grooves of the

30fixed shaft 33 to the upper vessel 26 of the hook. From here, the oil passes through the bore-hole 27 into the lower vessel 34. The smaller

31portion of this oil is conveyed by centrifugal force through an oil pipe 35 to the hook race. The major part of the oil flows again down and lubricates the gears 30 and the ball bearing 28.

Oil backflow from the hook case to the oil sump

32The pump 18 on the hook driving shaft sucks the oil from the hook case via the pipe 16 back to the oil sump.. The filter 14, contained in

33this pipe, intercepts soil particles and avoids thus disturbances of the pump functions. The pump 12 sucks the oil from the outer plastic tray via the oil felt 15 and via the duct 15..

2.10.3Checking oil level and oil supply

Caution: Danger of bodily injuries !

The machine must be in the position "Safe motor stop ".

–Check the oil level in the oil sump through the sight glass 10 while the machine is out of operation.

Top up if the oil level is in the lower third of the sight glass.

–Check the oil supply to the sewing head through the sight glass 5 while the sewing machine is in operation, e.g. during the automatic cycle.

–Check the oil level through the sight glass 17 of the hook case when the latter is in the sewing position and the sewing machine is out of operation.

28

2.10.4 Adjusting the hook lubrication

Caution: Danger of bodily injuries !

Do not introduce your hands into the area of the moving machine parts.

1

2

3

Rule and control

The hook should be lubricated safely with the lowest possible oil quantity. (This will also reduce the oil consumption)

–Lower the sewing machine head by the function "Lifting/lowering the machine head".

–Select the "speed" function.

Enter by the numerical keys "4000" and confirm by the "RETURN" key

–Remove the fabric rest.

–Press the key "F2".

Allow the sewing machine operate for about 1 minute.

–Press the key "F3".

–Hold a piece of paper beside the hook.

–Let the machine run at intervals of about 15 seconds by pressing the keys "F2" and "F3".

The adjustment is correct if enough oil is splashed onto the paper.

Correction

–Remove the bobbin case and the covering sheet 3, for being able to recognise the position of the small oil pipe.

–By means of a socket spanner, having an opening of 1.5 mm, turn back the screw 1 until the small oil pipe 2 does no longer move. Normally, said pipe will not move when it stands in the middle of the bore-hole.

–Tighten the screw 1 until the pipe begins to move.

–Turn the screw again by 1/8 revolution.

The adjusted oil quantity will decrease with the increasing distance of the pipe from the middle of the bore-hole.

–By means of a socket spanner, turn the screw 1clockwise for reducing the oil quantity.

Turn the screw 1 counter-clockwise for increasing the oil quantity. Please note the following:

The adjustment range between the maximum and the minimum oil quantity corresponds to a quarter (1/4) revolution of the screw..

ATTENTION !

The small oil pipe will be squeezed if the screw 1 is turned-in excessively.

Note

For ensuring a safe lubrication of the machine during its run-in time, the factory-set oil quantity is rather high. Therefore, following the run-in time, check and, if required control the oil quantity.

29

2.10.5 Oil change

1	2	3

Caution: Danger of bodily injuries !

Turn off main switch.

Switch off the machine before proceeding to the oil change

The oil should be changed after the first 500 service hours as follows:

–Remove the oil sump cover.

–Such the oil. If sucking is impossible,

loosen the drain screw 3 and let the oil flow out.

–Clean the oil sump and the breather tube.

–Turn-in the drain screw 3 after having replaced its gasket.

–Pour "ESSO SP-NK 10" oil through the filler neck 6 (s. page 26) until the oil level stands in the upper third of the oil sight glass.

2.10.6 Topping-up oil

Caution: Danger of bodily injuries !

Turn off main switch.

Turn off the machine before replenishing.

Top up if, during the operation of the machine, the oil level stands in the lower third of the sight glass 2 or when no oil supply can be seen through the sight glass 5 (s. page 26).

Fill "ESSO SP-NK 10" oil through the filler neck 6 (s. page 26) until the oil level stands in the upper third of the sight glass.

Other oil brands with the following specifications may be used:

Viscosity at 40°C:	10 mm2/s
Point of inflammation:	150 °C

30