Duerkopp Adler 4180i -1 Service Manual
Instructions for service
4180i - 1
Minerva Boskovice, a.s., Sokolská 60, CZ - 680 17 Boskovice
Tel.: +420-516-453434, 453433, 494111 Fax: +420-516-452165 http://www.minerva-boskovice.com
Edition: 10/2005 Printed in Czech Republic S735 000662
CONTENTS:
1. General safety instructions .............................................................................................................................................................. 1
2.
Introduction .......................................................................................................................................................................... 1
3. Head of the sewing machine .............................................................................................................................................. 2
Hook and hook post ................................................................................................................................................................ 2
3. 1
.. 3.1.1
3.1.2 Height setting of the hook
3.1.3 Setting the distance of the hook from the needle
3.1.4 Angular setting of the hook (timing)
3.1.5 Protection of the needle and of the hook point
3.1.6 Setting of the bobbin case opener
3.1.7 Setting the regulation of the hook lubrication
3.1.8 Replacement of the hook
3.1.9 Setting the gear
3.1.10 Dismantling of the hook post
3.2 Needle and thread mechanism ................................................................................................................................. 5
3.2.1 Description
3.2.2 To check the handwheel angular adjustment
3.2.3 Height setting of the needle bar
3.2.4 Side setting of the needle bar holder
3.2.5
3.3 Throat plate and its post ........................................................................................................................................................ 7
3.3.1 Description
3.3.2 Mounting and removing the throat plate and its insert
3.3.3 Side setting of the throat plate post
3.4 Thread tensioners and limiter ................................................................................................................................. 8
3.4.1 Description
3.4.2 Setting the tension of main and auxiliary tensioners
3.4.3 Setting the tensioning mechanisms of the main tensioners
3.4.4 Setting the adapting spring
3.4.5 Setting the thread limiter
3.4.6 Setting the
3.5 Feeding mechanism of the needle feed and of the lower feed wheel ........................................................................ 10
3.5.1 Description
3.5.2
3.5.3
3.5.4
3.6 Feeding mechanism of the top roller ....................................................................................................................15
3.6.1 Description
3.6.2 Side setting of the indented lower pulley
3.6.3 Side setting of the indented upper pulley
3.6.4 Setting the tensioning roller
3.6.5 Replacement of the indented belt
Description
Setting the needle (the needle bar holder) in the direction of sewing
additional thread limiter
Stitch length mechanism
3.5.2.1 Setting the upper eccentric
3.5.2.2 Setting the prop
3.5.2.3 a Forward and rearward stitch length distribution (rough)
3.5.2.3 b Forward and rearward stitch length distribution (fine)
3.5.2.4 Setting of the control knob (including the stitch length limitation)
Lower feed wheel
3.5.3.1 Feeding clutches
3.5.3.1.1 Description
3.5.3.1.2 Setting the lever of the second step of feeding(angle, position)
3.5.3.1.3 Setting of the lower eccentric
3.5.3.1.4 Setting the engagement and disengagement of the clutches
3.5.3.2 Wheel feeder and its post
3.5.3.2.1 Height setting of the feeder and tensioning of the chain
3.5.3.2.2 Replacement of the feeder
Setting the top roller (pressing force, height)
3.6.6 Top roller
3.6.6.1 Selection of the top roller diameter
3.6.6.2 Forward, rearward and side setting
3.6.6.3 Setting the gear clearance and in the mounting of the top roller
3.6.6.4 Replacement of the top roller
3.7 Setting the presser foot lift .................................................................................................................................... 19
Bobbin winder ....................................................................................................................................................... 20
3.8
Description
3.8.1
3.8.2 Setting the bobbin winder stop
3.8.3 Setting the friction gear
3.9 Safety clutch .......................................................................................................................................................... 21
Description
3.9.1
3.9.2 Setting the disengaging moment
3.10 Indented belt transmission ................................................................................................................................... 21
Setting the tensioning roller of the indented belt
3.10.1
3.10.2 Replacing the indented belt
3.11 V-belt, motor - head .............................................................................................................................................. 22
Tensioning
3.11.1
3.11.2 Replacing the V-Belt
3.12 Driving toothed belt ............................................................................................................................................................... 22
To exchange the driving toothed belt
3.12.1
3.13 Lubrication .............................................................................................................................................................................. 23
Description
3.13.1
3.13.2 Refilling oil
3.13.3 Multiple oil use
4. Thread trimming .................................................................................................................................................................................24
Description of the trimming mechanism
4.1
4.2 Setting the pickup roller
4.3 Setting the cam
4.4 Setting the fork
4.5 Setting the moving knife
4.6 Setting the height of the fixed knife and of the retaining spring of the lower thread
4.7 Setting the fixed knife
4.8 Setting the retaining spring of the hook thread
4.9 Setting switching of the electromagnets
5. Lifting the top roller by electromagnet ........................................................................................................................... 26
Description
5.1
5.2 Setting the electromagnet pin
5.3 Setting the electromagnet current
5.4 Assembly of the top roller lifting electromagnet
6. Backtacking using electromagnet .................................................................................................................................... 27
Description
6.1
6.2 Electromagnet height setting
6.3 Setting the position of push-buttons
6.4 Change of the function of push-buttons
7. Connecting the electric elements on the machine head ................................................................................................ 28
Drive, control panel, position sensor ......................................................................................................................................... 28
8.
Maintenance (table of operations) ............................................................................................................................................... 29
9.
Setting the machine according to the sewing category ............................................................................................................ 29
10.
Introduction
10.1
10.2 Table of setting the machine according to the sewing category
1. General safety instructions
The non-observance of the following safety instructions can cause bodily injuries or damages to the machine.
1. The machine must only be commissioned in full knowledge of the instruction book and operated by persons with appropriate
training.
2. Before putting into service also read the safety rules and instructions of the motor supplier.
3. The machine must be used only for the purpose intended. Use of the machine without the safety devices is not permitted.
Observe all the relevant safety regulations.
4. When gauge parts are exchanged (e.g. needle, top roller, needle plate, feed dog and bobbin) when treading, when the
workplace is left, and during service work, the machine must be disconnected from the mains by switching off the master
switch or disconnecting the mains plug.
5. Daily servicing work must be carried out only by appropriately trained persons.
6. Repairs, conversion and special maintenance work must only be carried out by technicians or persons with appropriate
training.
7. For service or repair work on pneumatic systems the machine must be disconnected from the compressed air supply system.
Exceptions to this are only adjustments and function checks made by appropriately trained technicians.
8. Work on the electrical equipment must be carried out only by electricians or appropriately trained persons.
9. Work on parts and systems under electric current is not permitted, except as specified in regulations DIN VDE 0105.
10. Conversions or changes to the machine must be authorized by us and made only in adherence to all safety regulations.
11. For repairs, only replacement parts approved by us must be used.
12. Commissioning of the sewing head is prohibited until such time as the entire sewing unit is found to comply with EC
directives.
It is absolutely necessary to respect the safety instructions marked by these signs.
Danger of bodily injuries !
Please note also the general safety instructions.
IMPORTANT WARNING
In spite of all safety measures made on the machines, inappropriate actions of the operator may lead to dangerous situations. In
industrial sewing machines, attention should be paid to the following still remaining possible sources of injury:
1. Moving sewing needle
- risk of injury when sewing with raised pressure foot or top roller, because the finger guard is then positioned too high,
- risk of injury when inadvertently threading down of the motor threadle.
2. Moving thread take-up lever
- risk of injury when inadvertently or intentionally inserting the finger(s) between the thread take-up lever and its guard.
3. Moving pressure member
- risk of injury when holding sewn work in immediate vicinity of the pressure member and beginning to insert under the
pressure member a considerably thicker sewn work portion,
- risk of injury when sinking the pressure member.
4. When switched off, the clutch motor slows down by inertia but would be reactivated by an accidental treading down of the
motor treadle. To avoid such risk, it is advised to hold the handwheel by hand and slightly to depress the motor treadle.
2. Introduction
This service book contains instruction for regulating the mechanisms of the sewing machine head.
The instructions for use and for putting the machine into operation and for the control of the stopmotor are not included in this
service book, but they are supplied as separate publications.
This service book is universal for all subclasses of the machine - it contains setting procedures for all elements which may be
placed on the machine of the given class. When the supplied subclass of this machine does not include some element, then it is
possible to leave out the respective parts of the instructions. The optional equipments of the machine and the respective
configurations of the subclasses of the machine are given in the operating instructions.
This sewing machine disposes of a large extent of its use. The machine should be set with respect to the parameters of the sewn
material, the sewing thread etc. The setting for the individual categories is given in the chapter 10.2.
For setting the machine, simple setting aids are used which are included in the accessory of the machine. Besides these aids,
universal measuring devices are used, such as slide calliper, feeler gauges and dynamometer for measuring the thread tension.
1
3. Head of the sewing machine
3.1 Hook and the hook post
3.1.1 Description
The hook (1) is mounted on the shaft (2) and is driven by the gear (3)
from the shaft (4).
The shaft of the hook (2) is mounted on the top in a sliding bearing
and, on the bottom, in a needle bearing.
The hook is provided with a lever (6) which is tilted when removing the
bobbin (7). The protecting sheet (8) protects against the collision of
the needle with the hook point. The bobbin case opener (9) is driven by
the eccentric (10) on the shaft (2).
The lubricating tube (11), on which a lubricating wick is fastened in the
tube (12), feeds oil for lubricating the sliding bearing (5) of the eccentric
(10) and the hook path.
The screws (13) serve for taking up the clearance of the gear. The
screws (14) fasten the post to the bedplate.
The lubricating felt (15) is connected by the wick (16) with the lubricating
system and serves for lubricating the gear (3).
13
15
67
8
10
1
9
5
11
12
2
16
3
4
14
3.1.2 Height setting of the hook
The designated distance A should be 5 mm.
Caution! Danger of injury!
Switch off the main switch ! Before starting the setting
3
4
7
5
2
6
A
6
- Loosen both screws (2).
- By turning the screws (3 and 4), set the required distanceA.
setting up use the setting gauge (7) as per the repective
figure. After having set it, tighten carefully the screws.
- By axial shifting of the gear wheel (5), set the axial clearance in
such a way that this clearance is the least possible, but sufficient for
turning easily the hook.
- Tighten carefully the screws (2). Caution ! One of these screws must
bear on the flat of the shaft 6).
operation, wait until the motor stops!
For
3.1.3 Setting the distance of the hook from
max. 0,1
2
The hook point (1) is set up to the maximum distance of 0.1 mm from
the bottom of the needle recess (2). For setting up use the needle size
100.
1
4
- Shift the plate (3).
5
- Loosen only one screw (4).
- Loosen the screws (5) and tighten them only slightly.
6
4
- Shift the hook post (6) at the determined distance between the needle
- Tighten carefully the screw (4) (be sure not to damage the threads!)
- Tighten duly the screws (5).
- Check up the setting using a narrow strip of thin paper and proceed
5
3
2
the needle
Caution! Danger of injury!
Switch off the main switch ! Before starting the setting
operation, wait until the motor stops!
and the hook point.
to the eventual correction of setting.
2
1
57
208
3
o
4
~ 0,5
6
3.1.4 Angular setting of the hook (timing)
The hook is to be angularly set in such a way that the hook point (1) is
opposite the needle at the moment, when the needle shifts by 2.5 mm
from its bottom dead center. This corresponds to the 2O8
of the handwheel (3).
Caution! Danger of injury!
Switch off the main switch! Before starting the setting
operation, wait until the motor stops!
- Remove the throat plate.
- Turn the handwheel (3) to the 2O8
which is component part ot the accessory of the machine (tighten
it carefully).
- Loosen the screws (5).
- Turn the hook into the required position.
- Set up the distance of about 0,5 mm between the gear wheel (6) and
the pin (7).
- Tighten to the maximum the screws (5).
° and fix it with the screw (4)
° on the scale
3.1.5 Protection of the needle and of the hook point
The protecting sheet (1) is to be set up in such a way that the clearance
between the protecting sheet and the needle (2) is the least possible.
2
5
3
4
1
6
3
- Remove the throat plate.
- In deforming the protective sheet (1) set the required play between
the sheet and the needle (2). After having introduced a suitable
screwdriver between the protective sheet and the hook body (3) we
shall reduce the play by levering, in applying the pressure on the
protective sheet in the sense of the arrow (4), we shall increase the
play.
- Check up the protecting effect in pushing against the needle in the
sense of the arrow (5). The hook point must not catch the needle. If
so, set up the protecting effect, correct eventually the setting of the
distance of the hook point from the needle according to the paragraph
3.1.3.
3.1.6 Setting of the bobbin case opener
The bobbin case opener (1) is to be set in such a way that, at the
moment when the opener is in its dead centre, there would be a clearance
A between the opener (1) and the projection (2), whereas the finger
(3) bears on the projection (4), A = 0.7 mm .
4
Caution ! Danger of injury!
Switch off the main switch! Before starting the setting
operation, wait until the motor stops!
Caution ! Danger of injury!
Switch off the main switch! Before starting the setting
operation, wait until the motor stops!
1
2
A
5
o
295
- Remove the sheet guard of the hook post.
- On the handwheel (5), set the angle of 295
centre).
- Loosen the screw (6).
- Turn the eccentric (7) in such a way that the required clearance
between the elements (1) and (2) is attained.
- Set the height of the eccentric (7) in such a way that it is in its
highest position in retaining the minimum clearance between the
slide (8) and the fork (9).
- Tighten duly the screw (6).
° (the hook is in its dead
78 69
3
6 7
0,4
11
3.1.7 Setting the regulation of the hook lubrication
5
3
4
9
15
1
2
o
10
1
8
By turning the lubricating tube (1) in the sense of the arrow (2), the
size of the contacting surface between the wick (3) and the felt insert
(4) is regulated. In this way, the speed of the capillary lift of oil into the
felt insert (5) is influenced, from which oil is wiped on the surface (6)
and is driven by centrifugal force into the hook path (7).
Setting of full lubrication
- Turn the screw (8) into the position (9).
Setting of limited lubrication
- Turn the screw (8) into the position (10).
After having ended the regulation, set the height of the lubricating tube
(1) at 0.4 mm from the eccentric (11).
1
2
3
4
3.1.8 Replacement of the hook
Caution! Danger of injury!
Switch off the main switch ! Before starting the setting
operation, weit until the motor stops!
- Remove the throat plate and the trimming knife.
- Unscrew the screws (1) and remove the gib (2).
- After having suitably turned a bit the hook, remove the bobbin case
(3).
- Unscrew thorougly the screw (4).
- Remove the body of the hook (5) upwards.
- When mounting, the procedure is inverse.
5
3.1.9 Setting the gear
4
1
3
5
The mutual angular orientation of the gear wheel (1) relative to the gear
wheel (2) should ensure the accessibility of the screw (5) at the moment
when the hook point comes to lie opposite the needle (4). The wheel
(2) is to be set with its gear rim symmetrically to the centre of the gear
wheel (1). The clearance between the gear wheels is to be the least
possible.
2
- Set the angle of 2O8
screw (7).
~0,5
208
8
9
6
10
o
10
7
- On the removed post of the hook (8), according to the paragraph
3.1.10, the hook point (3) is to be turned a bit according to the
illustration.
- Turn the gear wheel (2) into the suitable position and insert the post
of the hook into the machine according to the respective arrows.
Check up, whether the screw (5) is accessible and, if not, repeat the
procedure.
- Set the the distance of the hook from the needle according to the
paragraph 3.1.3.
- Set the precise angular displacement of the hook according to the
paragraph 3.1.4.
- Loosen the screw (10) and tighten them slightly.
- Set the clearence in the gear in turning the screws (9). Check up,
whether the gear has a clearance during the whole revolution of the
hook. Turn the handwheel step by step by 15
grasp the hook and try, if there is an angular dead travel. Tighten
carefully the screws (9).
- Tighten duly the screws (10) and try anew the clearance of the gear.
Caution ! Danger of injury!
Switch off the main switch! Before starting the setting
operation, wait until the motor stops!
° on the handwheel (6) and lock it with the
° and, with each step,
4
7
8
1
32
5
6
9
6
3.1.10 Dismantling of the hook post
When dismantling the post (1), the supplies of lubricating oil are to be
disconnected first, the fastening screws unscrewed and, thereafter, the
post is removed.
Caution ! Danger of injury!
Switch off the main switch! Before starting the setting
operation, wait until the motor stops!
- Unscrew the screw (2).
- Push the lubricating tube (3) downwards into the post.
- Unscrew the screw (7) from the oil tank (8) and pull the tank out
from the machine.
- Disconnect the hose with the wick (9) from the oil tank (8).
- Loosen only one screw (5).
- Unscrew the screws (6).
- Shift the post in the sense of the arrows and remove it out from the
machine.
- When mounting it, proceed inversely.
3
8
9
10
11
4
5
2
7
13
1
12
3.2 Needle and thread mechanism
3.2.1 Description
The take-up lever (1) is mounted in ball bearings, both at the spot of its
suspending on the connecting rod (2) and in the mounting on the loop
(12). The take-up lever is of aluminum and is provided with a stuck-in
eye for two threads. The connecting rod (2) is mounted on the eccentric
pin (3). The needle rod holder (4) is mounted through the pivot (5) in
a rotating way in the arm (6). In its top part, the holder is guided by the
guide pin (7). The movement for the needle feed is given to it by the
connecting rod (8) driven by the feeding shaft (9). The connecting rod
(8) is mounted by pin (13) with needle bar holder (4).
The connecting rod (10) of the needle bar (11) on the loop (12) is
mounted in a ball bearing and it is slidingly mounted on the needle bar
carrier. The mechanism is lubricated by means of a central-wick
lubricating system.
6
3.2.2 To check the handwheel angular adjustment
2
5
3
4
The handwheel (5) must be situated in its precise position relative to
the needle and thread mechanism. This position is given by a pin (2),
which locks the connecting rod of the needle rod (1) through a hole in
the arm (3). In this position, the indicator (6) of the handwheel must
show O. The position is fixed by the handwheel screw (4) contacting
a small flat surface provided on the upper shaft.
The correct adjustment of the angular position has been car-ried out at
o
0
the producers.
Caution ! Danger of injury!
6
Switch off the main switch! Before starting the setting
operation, wait until the motor stops!
1
3.2.3 Height setting of the needle bar
At the moment, when the hook point passes around the needle, the
upper edge of the needle eye must be about 1 mm below the hook
point. In an opposite case, it is necessary to set the height of the needle
bar as follows:
Caution ! Danger of injury!
Switch off the main switch! Before starting the setting
operation, wait until the motor stops!
- Remove the front guard.
1
1
- Loosen the screw (1) of the needle bar carrier
- Set the correct height of the needle bar and tighten anew the screw
(1).
Caution !
An incorrect setting of the needle bar height may cause
the striking of the hook point against the needle.
5
4
A
1
2
5
3
3.2.4 Side setting of the needle bar holder
The correct position of this holder is in such case, when the needle bar
is lined up with the presser-foot bar. The needle bar holder can be set
as follows:
Caution! Danger of injury!
Switch off the main switch! Before starting the setting
operation, wait until the motor stops!
- Loosen the screw (1) of the pin (2).
- Loosen the screw (3) of the guide pin (4).
- In shifting the pin (2) set the needle bar holder on the measure A
(distance between the front face of the arm and the front face
= 8 mm
of the safety bolt (5) of the needle bar holder)
pin (4) shifts/.
- The guide pin (4) is to be set in such a way that the needle bar holder
moves easily.
- Tighten the screws (1 and 3).
/at the same time the
1
3
3.2.5 Setting the needle (the needle bar holder)
in the direction of sewing
o
246
2
A
5
4
When shifting out the needle from the throat plate insert, at the moment,
when the needle eye is at the level of the top surface of the throat plate
insert (3), the distance between the needle and the wall of the throat
plate insert must be A = 0.2 mm.
Caution ! Danger of injury!
Switch off the main switch! Before starting the setting
operation, wait until the motor stops!
- Set the maximum allowed stitch length.
- Set the handwheel (1) to the angle of 246° and lock it with the screw
(2).
Loosen the screw (4) of the lever (5).
-
- By turning the needle bar holder (6) on the pin (7) set the required
distance A = 0,2 mm.
- Tighten up the screw (4) and check up the setting.
6
Caution!
7
A faulty setting may cause bending or breaking of needles
against the throat plate insert.
6
3.3 Throat plate and its post
4
2
4
1
32
5
6
3
1
3.3.1 Description
The throat plate (1) is equal for both categories of sewing. In the throat
plate there is fixed by means of two screw (3), (4) the exchangeable
throat plate insert (2). Each category of sewing has its own insert of the
throat plate which differ one from another by the length and width of
the piercinghole.
3.3.2 Mounting and removing the throat plate and
its insert
When mounting the throat plate (1), the finger of the hook (2) must fit
into the recess (3) of the throat plate. When demouting or replacing the
throat plate insert (4), both screws (5), (7) are to be unscrewed and the
insert romoved.
7
Caution! Danger of injury!
Switch off the main switch! Before starting the setting
operation, wait until the motor stops!
6
- Turn slightly the finger (2) in the sense towards the throat plate (1).
- Place the throat plate (1) and screw in the screws (6).
- Place the insert (4) and screw in the screws (5), (7).
3.3.3 Side setting of the throat plate post
The post of the throat plate (1) is to be side set in such a way that the
axis of the hole in the insert of the throat plate (2) is at the distance A
= 0.1 mm to the right from the axis of the needle (3).
3
A
4
- Loosen the screws (4 and 5) (from the rear side of the post as well).
2
1
- Shift the post (1) in the sense required for attaining the distance A
= 0.1 mm.
- Tighten the screws (4 and 5) and check up for the correct setting.
Caution! Danger of injury!
Switch off the main switch! Before starting the setting
operation, wait until the motor stops!
5
7
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