Duerkopp Adler 4260 - 6 Service Manual

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Instructions for service

4260 - 6

Minerva Boskovice, a.s., Sokolská 60, CZ - 680 17 Boskovice

Tel.: +420-501-453434, 453433, 494111 Fax: +420-501-452165 http://www.minerva-boskovice.com

Edition: 05/2002 Printed in Czech Republic 735 342 000 499

CONTENTS:

1. General safety instructions ............................................................................................................................................................. 1

2. Introduction ........................................................................................................................................................................................... 1

3. Head of the sewing machine ........................................................................................................................................................... 2

3. 1 Hook and the hook post ........................................................................................................................................................ 2

3.1.1 Description

3.1.2 Height setting of the hook

3.1.3 Setting of 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 Angular setting of the pin of the thread mechanism

3.2.5 Side setting of the needle bar holder

3.3 Throat plate and its post ...................................................................................................................................................... 7

3.3.1 Description

3.3.2 Side setting of the throat plate post and setting of the needle bed shifting

3.3.3 Setting the needle (the needle bar holder) in the direction of sewing (fine setting)

3.4 Front and rear guides of needles ......................................................................................................................................... 7

3.4.1 Description

3.4.2 Setting the front guide

3.4.3 Setting the rear guide

3.4.4 Setting the guide of the needles (stitch widths with needles, side by side)

3.5 Thread tensioners and limiter ............................................................................................................................................. 9

3.5.1 Description

3.5.2 Setting the tension of the main and auxiliary tensioners

3.5.3 Setting the tensioning mechanism of the main tensioners

3.5.4 Setting the adapting spring

3.5.5 Setting the thread limiter

3.6 Feeding mechanism of the lower feed wheel .................................................................................................................. 11

3.6.1 Description

3.6.2 Stitch length mechanism

3.6.2.1 Setting the upper eccentric

3.6.2.2 Setting the prop

3.6.2.3 a Forward and rearward stitch length distribution (rough)

3.6.2.3 b Forward and rearward stitch length distribution (fine)

3.6.2.4 Setting the control knob (including the stitch length limitation)

3.6.3 Lower feed wheel

3.6.3.1 Feeding clutches

3.6.3.1.1 Description

3.6.3.1.2 Setting the lever of the second step of feeding(angle, position)

3.6.3.1.3 Setting of the lower eccentric

3.6.3.1.4 Setting the engagement and disengagement of the clutches

3.6.3.2 Wheel feeder and its post

3.6.3.2.1 Height setting of the feeder and tensioning of the chain

3.6.3.2.2 Replacement of the feeder

3.6.4 Setting the top roller (pressing force, height)

3.7 Feeding mechanism of the top roller ............................................................................................................................... 16

3.7.1 Description

3.7.2 Side setting of the indented lower pulley

3.7.3 Side setting of the indented upper pulley

3.7.4 Setting the tensioning roller

3.7.5 Replacement the indented belt

3.7.6 Setting the feeding difference

3.7.7 Replacement of friction wheels of the drive conversion unit

3.7.8 Top roller

3.7.8.1 Selection of the top roller diameter

3.7.8.2 Forward, rearward and side setting

3.7.8.3 Setting the gear clearance and in the mounting of the top roller

3.7.8.4 Replacement of the top roller

3.8 Setting the top roller lift ..................................................................................................................................................... 20

3.9 Bobbin winder ..................................................................................................................................................................... 21

3.9.1 Description

3.9.2 Setting the bobbin winder stop

3.9.3 Setting the friction gear

3.10 Safety clutch ......................................................................................................................................................................... 22

3.10.1 Description

3.10.2 Setting the disengaging moment

3.11 Indented belt transmission ............................................................................................................................................... 22

3.11.1 Setting the tensioning roller of the indented belt

3.11.2 Replacing the indented belt

3.12 V-belt, motor - head ............................................................................................................................................................ 23

3.12.1 Tensioning

3.12.2 Replacing the V-Belt

3.13 Driving toothed belt.............................................................................................................................................................. 23

3.13.1 To exchange the driving toothed belt

3.14 Lubrication ............................................................................................................................................................................. 24

3.14.1 Description

3.14.2 Refilling oil

3.14.3 Multiple oil use

4. Thread trimming ............................................................................................................................................................................... 25

4.1 Description of the trimming mechanism

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 fixed knife

4.7 Setting the retaining spring of the hook thread

4.8 Setting the switching of the electromagnets

5. Lifting the top roller by electromagnet ...................................................................................................................................... 27

5.1 Description

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 ................................................................................................................................................ 28

6.1 Description

6.2 Electromagnet height setting

6.3 Setting the position of push-buttons

6.4 Change of the function push-buttons

7. Connecting the electric elements on the machine head ....................................................................................................... 29

8. Drive, control panel, position sensor ....................................................................................................................................... 29

9. Lighting ............................................................................................................................................................................................ 29

9.1 Mounting on the machine head

9.2 Lamp replacement

10. Maintenance (table of operations) ............................................................................................................................................. 30

11. Setting the machine according to the sewing category .......................................................................................................... 30

11.1 Introduction

11.2 Table of setting the machine according to the sewing category

11.3 Table of possible stitch widths of needles 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 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 functions 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. Conversion 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 Minerva, 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.

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 11.2.

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.

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

main lubricating system and serves for lubricating the gear (3).

3.1.2 Height setting of the hook

The designated distance A should be 6.1 mm.

max. 0,1

Caution! Danger of injury!

Switch off the main switch ! Before starting the setting

operation, wait until the motor stops!

- Loosen both screws (2).

- By turning the screws (3 and 4), set the required distanceA.

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).

3.1.3 Setting the distance of the hook from

the needle

The hook point (1) is set up to the maximum distance of 0.1

mm from the bottom of the needle recess (2). For the sewing

categories 1 and 2, the needle size 90 is set, for the sewing

categories 3 and 4, it is the needle size 160.

- Shift the plate (3).

- Loosen only one screw (4).

- Loosen the screws (5) and tighten them only slightly.

- Shift the hook post (6) at the determined distance between the

needle and the hook point.

- 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 to the eventual correction of setting.

Caution! Danger of injury!

Switch off the main switch ! Before starting the setting

operation, wait until the motor stops!

Caution!

When changing substantially the sewing catego-

ry, the protecting sheet of the hook (7) should be

set up.

205

~ 0,5

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 2O5° on the scale 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 2O5° and fix it with the screw

(4) 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).

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.

Caution ! Danger of injury!

Switch off the main switch! Before starting the setting

operation, wait until the motor stops!

- Remove the throat plate and the movable trimming knife.

- Unscrew the screw (3).

- Put the screwdriver into the hole of the screw (3) and, using the

regulating screw, set up the required clearance between the

needle (2) and the protecting sheet (1). When turning to the

right, the protecting sheet shifts out from the groowe and

inversely.

- 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 accord-

ing to the paragraph 3.1.3.

- Screw in the screw (3).

295

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

for the sewing category 1 and 2, A = 0.3 mm for the sewing

category 3 and 4.

Caution ! Danger of injury!

Switch off the main switch! Before starting the setting

operation, wait until the motor stops!

- Remove the sheet guard of the hook post.

- On the handwheel (5), set the angle of 295° (the hook is in

its dead 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).

6 7

0,4

3.1.7 Setting the regulation of the hook lubrication

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).

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.

3.1.9 Setting the gear

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.

Caution ! Danger of injury!

Switch off the main switch! Before starting the setting

operation, wait until the motor stops!

~ 0,5

205

- Set the angle of 2O5° on the handwheel (6) and lock it with the

screw (7).

- On the removed post of the hook (8), according to the pa-

ragraph 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° and, with

each step, 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.

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.

- Disconnect the hose with the wick.

- 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. Make sure that the

wicks in the tubes are in contact with the other wicks leading

oil into the box (7).

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 pin (3). The needle bar holder (4) is mounted

through the pin (5) in a rotating way in the arm (6). In its upper

part, the holder is fastened with the screw (7).

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.

3.2.2 To check the handwheel angular adjustment

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 the producers.

Caution ! Danger of injury!

Switch off the main switch! Before starting the

setting operation, wait until the motor stops!

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.

- 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.

3.2.4 Angular setting the pin of the thread

mechanism

The hinged pin (2) of the connecting rod (3) can be set in

three positions (the pin has got 3 flats ground for the screw):

- for the hook of small diameter (value A  minimum)

- for the hook of large diameter , sewing category 100 and

200 (value A = medium)

- for the hook of large diameter, sewing category 300 and

400 (value A  maximum)

The value A is to be measured in the bottom position of the

take-up lever. Set the pin of the connecting rod 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.

- Set the lowest (bottom) position of the take-up lever.

- Loosen the screw (1) of the pin (2) of the connecting rod (3).

- The position of the take-up lever is changed when turning

the pin (2).

- Set the pin (2)into the corresponding position and tighten

anew the screw (1).

The correct position is given by the flat on the pin (2), on

which the screw (1) is to be tightened.

3.2.5 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 pin (4).

- In shifting the pin (2) set the needle bar holder on the measure

A = 7.5 mm (distance of the front faces of the arm and of

the needle bar holder) /at the same time the 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).

3.3 Throat plate and its post

3.3.1 Description

The throat plate (1) is always for the given stitch width of

needles and universal for all respective categories of sewing

(see Tab. sewing equipments - Spare parts list).

In the throat plate there is mounted an exchangeable throat

plate insert (2). For each stitch width of needles, it is possible

to supply several throat plate inserts differing one from

another by the width of the piercing hole.

3.3.2 Side setting of the throat plate post and

The throat plate post (1) and the needle holder (2) are to be

mutually positioned in such a way, so that, with the given

stitch width A, both needles pass through the centres of the

needle penetration holes.

- Loosen the screw (3) of the needle bar carrier.

- Shift the needle bed (2) in such a way, so that the required

- Tighten up the screw (3) and check up the setting.

- Loosen the screws (4) /from the rear side of the post too/.

- Shift the post (1) in the right direction in such a way, so that

- Tighten up the screws (4) and check up the correctness of

setting of the needle bed shifting

Caution! Danger of injury!

Switch off the main switch! Before starting the

setting operation, wait until the motor stops!

stitch width of needles A" is attained.

both needles pass through the centres of the needle pene-

tration holes.

setting.

3.3.3 Setting the needle (the needle bar holder) in

the direction of sewing (fine setting)

Caution! Danger of injury!

Switch off the main switch! Before starting the

setting operation, wait until the motor stops!

- Loosen the screw (5).

- In turning the needle bar holder (7), set the needle against

the centres of the needle penetration holes.

- Tighten up the screw (5) and check up the setting.

Caution!

A faulty setting may cause bending or breaking of

needles against the throat plate insert.

3.4 Front and rear guides of needles

3.4.1 Description

The front guide (1) and the rear guide (2) are used together

for stitch widths of a tandem arrangement. For stitch widths

with needles side by side, the rear guide (3) is used only. All

guides serve for holding the sewn material against the throat

plate. In addition to this, they contribute to a as well and

protect the needles in guiding them into the piercing holes.

3.4.2 Setting the front guide

The front guide is universal for tandem stitch widths and for

all categories of sewing. It should be set in such a way that,

from the point of view of the operator, it protects the right

needle from the left-hand side. In the that, when backward

stitching, it could not negatively influence the stitch locking.

Its correct height is set up according to the sewn material

1-2 mm above the bottom edge of the feeding wheel. For

harder materials, it is set a bit lower and inversely.

Caution! Danger of injury!

Switch off the main switch! Before starting the

setting operation, wait until the motor stops!

- Loosen the screw (4) and set the correct height of the guide

(1). Tighten then the screw.

- Loosen the screw (5) and set the guide (1) in the direction

of sewing in front of the left needle at the moment, when

the needle starts piercing the material and set, at the same

time, the side clearance between the guide and the right-

hand needle, tighten then the screw.

- Check up the influence of the setting on the stitch locking.

3.4.3 Setting the rear guide

For different stitch widths of needles there is always used, for

all sewing categories, the respective guide (in each sewing

set there is supplied a corresponding guide). The rear guide

protects the left needle from the right-hand side. It is to be set

in such a way in the direction of sewing that it favourably

influences the stitch locking even when sewing the radii. Its

correct height is set 1-2 mm above the bottom edge of the

feeding wheel, namely according to the hardness of the sewn

material.

Caution! Danger of injury!

Switch off the main switch! Before starting the

setting operation, wait until the motor stops!

- Loosen the screw (6) and set the guide (2) in the direction

of sewing behind the right needle at the moment when the

needle leaves the sewn material, tighten up the screw.

- Loosen the screws (7) and set the guide in its correct height

and, at the same time, set the side clearance between the

guide and the left needle, tighten up the screw.

- Check up the influence of setting on the stitch locking.

3.4.4 Setting the guide of the needles (stitch

widths with needles, side by side)

The side setting of the guide is to be done starting from the

axis of the stitch width of the needles, that is to say that the

clearances between both needles and the guide must be the

same. The correct height of the guide is set up according to

the sewn material, 1-2 mm above the bottom edge of the

feeding wheel. In the sense of sewing, the guide is to be set in

such a way that the contact of the guide with the material is at

the same spot as the contact of the feeding wheel with the

material.

Caution! Danger of injury!

Switch off the main switch! Before starting the

setting operation, wait until the motor stops!

- Loosen the screws (7) and set the guide (3) into the axis of

the stitch width of the needles and set the guide in its

correct height, tighten the screws.

- Loosen the screw (6) and set the guide in the direction of

sewing according to the feeding wheel, tighten the screw.

- Check up the influence of setting on the stitch locking.

3.5 Thread tensioners and limiter

11 8

3.5.1 Description

The main tensioner (1) serves for creating the tension of the

threads when tightening the stitch. The auxiliary tensioner (2)

reduces the risk of pulling out of the thread after the thread

trimming when removing the sewn material, when the thread

is passed through this material and when the main tensioner

is relieved. The main tensioner is relieved by the mechanism

controlled by the shaft of the presser foot lifting (3), on which

the lever (4), is mounted which shifts the prop (5), which

pushes the metal sheet lever (6). This lever shifts the pin (7)

and this pin pushes onto the washer (8) and relieves the spring

(9).

With the machines provided with a thread trimming device,

the main tensioner (1) is relieved as well when switching on

the electromagnet (10), when its armature (11) pushes against

the lever (6). The mechanism of the adapting spring (12)

maintains the thread in its tensioned state when passing

through the hook. The thread limiter (13) limits the length of

the thread fed by the take-up lever when moving from the

upper to the bottom dead centre to get a controlled passing

of the thread through the hook.

3.5.2 Setting the tension of the main and auxiliary

tensioners

The tension of the main thread tensioner is regulated by means

of the nut (1). The force of tensioning the thread is measured

by the dynamometer (2) as it is shown on the illustration. The

size of this force differs according to the category of sewing

and is indicated in the par. 11.2.

The tension of the auxiliary tensioner is regulated using the

nut (3). It should be the least possible, but sufficient for

unthreading the thread from the sewn material when removing

the sewn material from the pressing element without leaving

the tensioner.

3.5.3 Setting the tensioning mechanism of

the main tensioners

The nut (1) must be screwed off in such a way that the metal

sheet lever (2) bears on the plate (3) and, at the same time, the

lever (4) is not limited by the prop (5) in its rotation. The lever

(4) must be fixed against the shaft (6) in such a way that,

when the presser foot is in its lowest position, the nut (1)

bears on the metal sheet lever (2) with its minimum clearance.

Caution ! Danger of injury!

Switch off the main switch! Before starting the setting

operation, wait until the motor stops!

- Unscrew thoroughly the nuts (7) and loosen the screw (8).

- Put in one line the axis of the shaft (6), the axis (9) and the axis

of the spherical surface of the nut (1).

- Unscrew the nut (1), until the metal sheet lever (2) strikes

against the plate (3). However, the lever (4) must rotate freely

in the sense of the arrows in both senses.

- Screw in the nuts (7) almost to the stop.

- Remove the sewn material and lower the presser foot.

- Turn the lever (4) in the sense of the arrow up to the stop.

- Return the lever (4) a bit back and tighten the screw (8).

3.5.4 Setting the adapting spring

The mechanism of the adapting springs is to be set up in such

a way that, when unscrewing the nut (1) up to the stop against

the washer (2), the conical springs (3) remain under the tension

which is to be set up by shifting the adjusting ring (4) locked

by the screw (1O).

The angular setting thereof is to be done in such a way that

the angle A = 45°. The axial setting is to be done in such a

way that the plate (5) and the plate (6) are at the mutual distance

equal to the measure C= 3 mm.

The washers (7) are to be oriented in such a way, so that the

distance B = 1 to 1.5 mm. The bushings (8) are to be oriented

in such a way that the adapting springs (9) are tensed up by

90° from their free state.

Caution! Danger of injury!

Switch off the main switch! Before starting the setting

operation, wait until the motor stops!

- Unscrew the nut (1) up to the stop towards the washer (2).

- Loosen the screw (10), push heavily the ring (4) against the

washer (2) and tighten the screw (10).

- Mount the mechanism of the adapting spring into the machine

in such a way, so that the pieces (5 and 6) are at the distance

C = 3 mm, set the angle A = 45° and tighten the screw

(11).

- Turn the washers with their noses (7) in such a way that the

distance B = 3 mm is attained.

- Put the screwdriver into the slit in the bushing (8) and turn it in

counterclockwise direction, until the spring (9) touches slightly

the nose of the washer (7). Turn then still the bushing (8) by

1/4 revolution.

- Tighten the nut (1). In this way, the whole mechanism im-

mobilizes.

3.5.5 Setting the thread limiter

The thread limiter is to be set in such a way that, when sewing and

passing the thread through the most distant point of the hook,

the spring (2) shifts by about 1/4 to 3/4 length of its total length.

This means that the thicker will be the sewn material and the longer

will be the stitch length, the more will be the limiter shifted in the

sense of the arrow and inversely. Under standard sewing

conditions, the thread limiter is set in its tested positions depending

on the sewing category in accordance with the chapter 11.

Caution! Danger of injury!

Switch off the main switch! Before starting the

setting operation, wait until the motor stops!

- Tighten the screw (3).

- Set the thread limiter (1) in such a way that the screw (3)

is situated above some letter according to the chapter 11.

- Tighten the screw (3).

3.6 Feeding mechanism of the lower feed wheel

3.6.1 Description

The feeding mechanism is formed by the leverage (1) which

is driven from the main shaft through the eccentric with connection

rod (2). The feeding movement is transmitted by the shaft (3)

by means of the draw bar (5) onto the clutch of the bottom

wheel feed (7).

The engaging and the disengaging function of the clutch (7)

is controlled from the lower shaft (8) through the eccentric with

the connecting rod (9) and through the wedge coupling (10).

The feeding movement is transmitted by the shaft (11) through

the chain transmission (12) onto the wheel feeder (13).

The stitch length is set by the knob (14) through the leverage (15)

to the feeding mechanism (1).

3.6.2 Stitch length mechanism

3.6.2.1 Setting the upper eccentric

The eccentric (1) is to be set at the respective angle in such a

way, so that the movement of the needle bar and the feeding

by the wheel feeder are correctly phase shifted one against

the other. This refers to the angle of 90° on the handwheel (2),

when the setting stick (3) is engaged into the eccentric (1)

and leans from above against the feeding shaft (4).

Caution! Danger of injury!

Switch off the main switch! Before starting the setting

operation, wait until the motor stops!

- Set the angle 90° on the handwheel (2) and lock it with the

screw (5) which is included in the accessory of the machine

(tighten it carefully).

- Insert the setting stick (3) into the hole in the eccentric (1)

and prop it against the feeding shaft (4).

- Shift axially the eccentric on the shaft up to its extreme

position to the right or to the left and place it in the medium

position.

- Tighten the screws of the eccentric (6) to the utmost (one

screw first and, in turning a bit the handwheel, another screw

too).

3.6.2.2 Setting the prop

In this machine with a wheel feed, the prop (1) is mounted in the

pits (A and C) as per the drawing.

3.6.2.3a Forward and rearward stitch length

distribution (rough)

The cam (1) is to be set at the respective angle in such a way that

the stirrup (6) is oriented in such a position, so that the connecting

678

rods (7 and 8) are in a line with a thoroughly screwed in knob (9)

and with turning the handwheel at 0°. This setting can be done

only after having set the top eccentric according to the pa-

ragraph 3.6.2.1.

Caution! Danger of injury!

Switch off the main switch! Before starting the setting

operation, wait until the motor stops!

- Set the zero stitch /screw in the knob (9) to the bottom of

the cam (1)/.

- Set the angle 0° on the handwheel and lock it with the screw

(4).

- Turn the screw (3) in the respective sense in such a way that

the connecting rods (7 and 8) are in a line and tighten the

screw (2).

3.6.2.3b Forward and rearward stitch length

distribution (fine)

When setting the maximum length of the stitch, the forward and

the rearward stitch length must be equal with the maximum error

of ± 5 %. This setting can be done only after having set the

wheel feed (par. 3.6.4.1.2).

- Set the maximum stitch length .

- Place a suitable material under the presser foot and mark therein

the forward and the rearward stitch length.

- With an unequal length of the stitch, proceed to the correction

of setting by turning the screws (2 and 3). When tightening the

screw (3), the forward length of the stitch is shortened and

inversely. When tightening the screw (2), the forward stitch

length is lenghtened. Tighten the screw (2).

Caution! Danger of injury!

switch off the main switch! Before starting the setting

operation, wait until the motor stops!

3.6.2.4 Setting the control knob (including the

stitch length limitation)

The control knob (1) is to be set up in such a way that, when

turning in the counterclockwise sense up to the stop, the

maximum stitch length valid for the given sewing category

and the stitch width is attained. The scale on the control knob

is to be oriented in such a position that the respective maxi-

mum stitch length on the scale is against the marking on the

machine arm.

- Screw in the screw of the control knob in such a way that

the spherical surface of the screw (3) bears on the seat of

the cam (4).

- Loosen the screw (5) and turn the control knob in the clockwise

direction, until the pin (6) of the knob (1) bears on the pin

128

(7). Tighten firmly the screw (5).

- The control knob (1) is to be set to the maximum stitch

length corresponding to the respective sewing category and

to the given stitch width. Check up the set up length by a

sewing test.

- Loosen the screw (5) and turn the control knob in the

counterclockwise sense, until the pin (6) of the knob (1)

bears on the pin (7). Tighten firmly the screw (5). Check it

up by a sewing test.

- Put a screwdriver into the hole (8) of the scale (2) and adjust

the scale in such a way that the respective maximum stitch

length on the scale is against the marking on the machine

arm.

Caution! Danger of injury!

Switch off the main switch! Before starting the setting

operation, wait until the motor stops!

3.6.3 Lower feed wheel

3.6.3.1 Feeding clutches

3.6.3.1.1

The feeding clutch with machines without the needle feeding

is identical with the clutch for the needle feeding. The

difference is in its function.Feeding is namely realized here by

one step. For this reason, the clutch lid (1) is firmly anchored

by the draw bar (2) and by the pin (15) in the machine arm.

The rotating motion of the shaft (6) is produced from the

oscillating motion of the draw bar (3) through the lever (14),

the star (4) and the driving disk (5) firmly connected with the

shaft (6).The clutch is coupled by means of the wedge (7) on

the connecting rod (8) through the eccentric (9) which is placed

on the lower shaft (10).

In the position, when the wedge is disengaged, the star (4)

is shifted out from the frictioning engagement with the lining of

the carrier plate (5) by means of the spring washer (11). The plate

(5) lining is then pushed by means of a flat profiled spring (2)

against the cover of the clutch (1).

In this phase, the shaft (6) is connected with the cover of the

clutch (1) which is connected with the machine arm, so that

the shaft (6) does not rotate and, consequently does not feed

the sewn work.

In the position, when the wedge is disengaged, the star (4)

is pushed against the plate (5) lining and, at the same time,

the friction connection with the cover of the clutch (1) is

disconnected. In this phase, the shaft (6) is connected with

the star (4) and is rotating, which means that it is feeding.

Within a short instant, when engaging and disengaging with

the carrier plate (5), there are in a friction engagement both

the cover (1) and also the star (4), namely in the dead centre of

the connecting rod (3). The setting of the change-over of

clutches is done by tightening or by loosening the nut (13).

Description

3.6.3.1.2 Setting the lever of the feeding

The feeding lever (1) must be set in such a way, so that, when

the needle is in its lower dead centre, the axis of a part of the

star (2) coincides with the axis of the screw (3).

Lever (1) displacement

- Loosen the screw (6).

- Set the maximum stitch length.

- Set the angle 180° on the handwheel.

- Unscrew the screw (5) and put the needle shank in its hole.

- Turn the lever (1) until the needle drops into the clutch disk (2).

- Side set the lever (1) to the measure A= 0.5 to 1 mm.

- Tighten the screw (6).

- Screw in the screw (5) and seal it with the Loctite cement.

(angle, position)

Caution! Danger of injury!

Switch off the main switch! Before starting the

setting operation, wait until the motor stops!

244

3.6.3.1.3 Setting of the lower eccentric

The rotation of the eccentric (3) must be delayed in phase by

1/4 revolution against the rotation of the eccentric of the stitch

length. This corresponds to the angle of 244° on the handwheel

(1), when the setting pin (4) is put into the eccentric (3) which

is in contact with the indented belt (5).

- Set 244° on the handwheel (1) and lock it with the screw

(2), which is included in the accessory of the machine

(tighten it carefully).

- Put the setting stick (4) into the hole in the eccentric (3) and

prop it from below against the indented belt (5).

- Set eccentric (3) axially.

- Tighten it the utmost the screws of the eccentric (6).

- By means of the handwheel, turn the eccentric (3) into the marked

position and check in this position the clearance A = 0.05,

proceed eventually to its correction by a new side setting of

the eccentric.

Caution! Danger of injury!

Switch off the main switch! Before starting the

setting operation, wait until the motor stops!

3.6.3.1.4 Setting the engagement and

disengagement of the clutches

Caution! Danger of injury!

Switch off the main switch! Before starting the setting

operation, wait until the motor stops!

The nut (7) is to be side set in such a way that the shifting of

the clutches is done at the moment when the clutch disks (3)

do not move, which means, when they are at the dead center

of their oscillating movement. This corresponds to the angle

90° on the handwheel.

- Loosen the screws of the indented pulley of feeding and shift it

to the left.

- Set the maximum stitch length.

- Set the angle 90° on the handwheel and lock it with the

screw (2). which is included in the accessory of the machine

(tighten it carefully).

- Loosen three screws (6) in the nut (7) and unscrew it by

2 mm to the left.

- Tighten slowly the nut (7), until it strikes against the axial

bearing (9). (At this moment, the tightening moment

increases in jumps) and tighten the screws (6).

- Set the hand wheel on 85° and depress the backtacking

lever, the feeder should turn against the sewing direction.

Set then the hand wheel on 95°, the feeder should not rotate.

If not being so, correct the side setting of the nut (7). When

the clutches shift too soon, turn a bit the nut (7) to the right

and inversely.

- Tighten the screws (6).

- Return the indented pulley in its original place according to the

paragraph 3.7.2.

3.6.3.2 Wheel feeder and its post

3.6.3.2.1 Height setting of the feeder and tension-

ing of the chain

The wheel feeder (1) is to be set in such a way that the points

of its teeth overtop the throat plate by X= 0.3 to 0.7 mm.

When sewing soft and thick materials, it is necessary to

increase the value X, until a good quality of feeding is

attained, but only to the measure of not deteriorating the

beginning of sewing after the carried out thread trimming.

With every correction of the teeth height, the tension of the

chain (2) is to be corrected.

Caution! Dangere of injury!

Switch off the main switch! Before starting the setting

operation, wait until the motor stops!

- Loosen the screw (3).

- Loosen the screw (4).

- Loosen or tighten the screw (5) and push simultaneously with

finger the feeder (1) downwards, until the required height of

the teeth X of the wheel feeder is attained.

- Tighten then still the screw (5) by 45° (1/8 revolution).

- Tension the tensioner (6) up to the stop. Be careful in side

shifting it to the centre of the chain. Tighten the screw (3).

- Loosen the screw (5) by 45° (1/8 revolution), into its original

position. In this way, the optimal clearance of the chain

transmission is attained.

- Tighten the screw (4).

- Correct the set height of the top roller according to the

par. 3.6.5.

3.6.3.2.2 Replacement of the feeder

For the replacement of the wheel feeder (change of the wheel

feeder according to the machine setting - see par. 11.2 - setting

of the machine - feeder - pitch of the teeth).

- Unscrew the screws (1) and remove the throat plate (2).

- Dismantle the hook of the left-hand post (see 3.1.8).

- In pulling upwards (securing by a spring), pull out the feeder

(3) with the guide (4).

- Replace the feeder (3).

- Insert the feeder with the guide into the groove of the holder

(5).

- Mount the hook of the left-hand post (see 3.1.8).

- Mount the throat plate (2) and tighten up the screws (1).

- Check up, if the spring (6) pushes the guide (4) with the

feeder (3) against the wheel (8).

- In the opposite case, loosen the screws (9),tense up the

spring in such a way,so that the guide (4) with the feeder (3)

is pushed against the wheel (8) and tighten the screws (9).

Caution! Danger of injury!

Switch off the main switch! Before starting the setting

operation, wait until the motor stops!

3.6.4 Setting the top roller (pressing force, height)

When lowering the top roller (1), set the clearance A between

the feeder (5) and the top roller to the maximum of 0.2 mm.

Set the pressing force of the top roller (1) so as to avoid the

slippage of the sewn material when feeding it.

Method of setting the height of the top roller:

- Lower by hand the presser bar (3) with the top roller (1)

above the wheel feeder (5).

- Loosen the screw (4) and set the required value A (0.2 mm).

- Tighten the screw (4).

Setting the force of the top roller (1).

- In screwing in the screw (2),the force of the top roller is

increased and inversely.

178131214

3.7 Feeding mechanism of the top roller

3.7.1 Description

The starting movement for the drive of the top roller feeder is the

bottom feeding shaft. From this shaft, the movement is transmitted

by the indented belt (1) onto the top feeding shaft (2). A component

part of the transmission by indented belt is the pulley (3), the

tensioning roller (4), the roller (5) and the pulley (6). Starting

from the shaft (2), the movement is further transmitted through

the friction wheels (7 and 8) of drive conversion unit onto the

articulated shaft (9). From this articulated shaft, the movement

is transmitted by a cone transmission, situated in the holder

(10), onto the feeder wheel (11). The drive conversion unit

serves for compensating the differences in feeding by the

driven top roller and by the lower feed wheeler. By turning the

screw (12), the change of the gear speed ratio is attained.

After having set in accordance with the par. 3.6.6, the screw

(12) in the holder (13) is to be locked by the nut (14). The

pressure of the friction wheels (7 and 8) is ensured by the

compression spring in the shaft (2). To avoid a complete

pushing out from the arm, the shaft is locked by a stirrup ring

(17). The shaft of the friction wheel (8) is mounted in the

screw (12) on needle bearings. The articulated shaft (9)

contains two joints (15) and a telescopic part (16). Both these

elements secure the lifting

and the tilting of the top roller.

3.7.2 Side setting of the indented lower pulley

The pulley must be set up in such a way that the belt passes

through the centre of the passing hole in the bedplate. The

setting operation is to be done as follows:

Caution! Danger of injury!

Switch off the main switch! Before starting the setting

operation, wait until the motor stops!

- Loosen the screws (1) of the pulley (2).

- Loosen the screw (3) of the tensioning roller (4)

- Set the pulley (2) in such a way that the belt (5) passes through

the centre of the passing hole in the bedplate (6).

- Tighten the screws (1).

- Set the tensioning roller (4) axially in such a way that the belt

(5) is set at the middle of the tensioning roller (4).

- Set the tensioning roller (see par. 3.7.4).

- Tighten up the screw (3) of the tensioning roller (4).

3.7.3 Side setting of the indented upper pulley

The pulley is to be set in such a way that the indented belt is

not crossed and the pulleys are in line. The setting thereof is

to be done as follows:

- Loosen the screws (1) of the pulley (2).

- Set the pulley (2) in such a way that the distance of 5 mm

is attained in accordance with the illustration.

- Tighten the screws (1).

Caution! Danger of injury!

Switch off the main switch! Before starting the

setting operation, wait until the motor stops!

3.7.4 Setting the tensioning roller

The tensioning roller of the indented belt of the top feeding

is mounted in a rotary way on the bedplate. The belt must be ten-

sioned as needed in such a way that there is ensured the correct

function of the transmission. Insufficient tension can cause

skipping of the teeth, on the contrary, excessive tensioning

enormously loads the mounting of the top shaft. The setting thereof

is to be done as follows:

Caution! Danger of injury!

- Loosen the screw (1) securing the lever of the tensioning roller

(2).

- Tension the belt as needed (theoretically, in applying the force

of 10 N in the middle of the belt with the deflection of 4 mm).

- Tighten the screw (1).

Switch off the main switch! Before starting the

setting operation, wait until the motor stops!

1110 12 438912

3.7.5 Replacement the indented belt

Before replacing the indented belt, the bottom feeding shaft

is to be removed. The procedure is 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 tensioning roller (2) and loosen it.

- Loosen the screws (3) of the pulley (4) and shift it to the left in

such a way that the screws (5 and 6) of the feeding clutch (7)

are accessible.

- Loosen the screws (5 and 6).

- Loosen the screw (8) of the axial ring (9).

- Loosen the screws (10) of the chain wheel (11).

- Push the shaft (12) to the left in such a way that it is out of the

pulley (4).

- Remove the pulley (4).

- Remove the front guard.

- Loosen and unscrew the screw (4) of the holder of the wheel

(15) and remove it from the holder (24).

- Loosen the screws (16 and 17) of the holder (18).

- Remove the holder (18) together with the holder (15) and

articulated shaft (13) from the machine.

- Loosen the screws (19) of the pulley (20).

- Remove the retaining ring (21) from the shaft (22).

- Hold the pulley (20) and pull out the feeding shaft (22) from

the arm in such a way that it is possible to remove the

indented belt (23) from the arm of the machine.

- Replace the belt with a new one and proceed to the assembly

(inverted procedure of dismantling).

- Proceed to the setting operation according to the par. 3.7.2,

3.7.3 and 3.7.4.

3.7.6 Setting the feeding difference

The size of feeding by the driven top roller is regulated by means

of a regulating screw. The top roller feeding is to be set in cases,

when a difference between the size of the top and bottom feeding

of the sewn material is evident. This will show up in upward or

downward bending of the sewn parts. It is therefore necessary,

when bending the sewn parts:

1. upwards - to increase the feeding performance of the top roller.

2. downwards - to reduce the feeding performance of the top

roller.

This setting operation is done as follows:

- Loosen the locking nut (1) of the adjusting screw (2).

- Turn the screw to the left (in increasing so the feeding perfor-

mance of the top roller) or to the right (in reducing so the feeding

performance of the top roller).

- Test the result of this setting in sewing.

- Tighten the locking nut (1).

- The standard setting for the zero difference is 3 mm (see

Fig.) - the gap between the front faces of the screw (2) and

the nut (1).

3.7.7 Replacement of friction wheels of the drive

conversion unit

The worn friction wheels (1 and 2) of the drive conversion unit are

to be replaced. This is done 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.

- Loosen and unscrew the screw (3) from the holder of the wheel

(4) and remove it from the holder (5).

- Loosen the screws (6 and 7) of the holder (8) and remove the

holder (8) with the telescopic shaft (9) and the driven wheel

from the machine.

- In pulling it out, remove the telescopic shaft (9) from the holder

(8).

- Loosen and unscrew the screw (10) and remove the shaft

(11) with the friction wheel (12) from the telescopic shaft.

- Press out the pin (13) from the shaft (11) and the wheel

(12).

- Replace the wheel (12) by a new one and proceed to a reassembly

(an inverse procedure to the dismantling).

- Loosen the screw (14) of the conic friction wheel (15).

- Remove the wheel (15) and replace it.

- Proceed to a reassembly (an inverse procedure to dismantling).

3.7.8 Top roller

3.7.8.1 Selection of the top roller diameter

The machine can be supplied with two types of top roller,

namely with the diameter of 25 mm and with the diameter of

35 mm. The suitability of the diameter used depends on the

type of sewing and on the concrete technological operation.

There are in general valid the following principles for the

selection of the wheel diameter:

ø 25 mm - for sewing small radii ø 35 mm- for sewing straight sections or big radii

- for sewing with great passages to thicker materials

3.7.8.2 Forward, rearward and side setting

The top roller must be in a defined position in relation to the

needle:

a)view (see Fig. 1) - the value X depends on the diameter of

obr. 2obr. 1

use top roller (

from the the needle bar up to the roller edge when turning

the handwheel to the 180° of the scale against the indicator

b)view (see Fig. 2) - the wheel edge must fit with the edge of

the left needle operture at the spot of the left needle punch.

These values are to be set as follows:

- Loosen the screw (1).

- By shifting the holder (2) with the top roller (3) in the groove of

the holder (4) set the required value X and tighten the screw(1).

- Loosen the screw (5)

- By shifting the holder (2) in the holder (6) set the bottom edge

of the roller to the edge of the needle operture.

- Tighten the screw (5).

ø 25 - 6.5 mm; ø 35 - 10.5 mm), it is measured

Caution! Danger of injury!

Switch off the main switch! Before starting the setting

operation, wait until the motor stops!

3.7.8.3 Setting the gear clearance

and in the mounting of the top roller

In the cone gear of the drive of the top roller, the minimum

clearance must be set. A too small clearance will increase the

friction resistance of the gear, the excessive clearance will

influence the inaccuracy of feeding. The top roller itself is

mounted on balls. With this type of mounting,it is also

necessary to set the minimal possible radial clearance.

The given clearances are set as follows:

Caution! Danger of injury!

Switch off the main switch! Before starting the setting

operation, wait until the motor stops!

Clearance in the wheel mounting

- Loosen three screws (5) /only slightly/.

- Using the screw (4) set the minimum clearance in the top

roller mounting (2) /it must easily rotate without any rubbing

and with a minimum clearance/.

- Tighten the screws (5), check the set up clearance, even-

tually, repeat the setting procedure.

Clearance in the conic gear

- Loosen the screw (1), in shifting the wheel, resp. the holder

(3) in the holder groove (6), set the minimum clearance,

the pinion (7) must be pushed up to the holder bottom (6).

- Tighten the screw (1), check the set up clearance.

3.7.8.4 Replacement of the top roller

When replacing the top roller, proceed as follows:

- Unscrew the screw (1).

- Unscrew the screw (3) with the washer (2).

- Remove the driven top roller with the holder (4) from the holder

(5) and from the articulated shaft (8).

- Mount another top roller in inverted procedure to dismantling.

- Set the top roller according to the par. 3.7.8.2.

3.8 Setting the top roller lift

The maximum lift of the top roller when lifting the foot with

knee lever or with electromagnet is to be A = 12.5mm.

- Place a cube (1) having the height of A = 12.5 ± 0.7 mm

under the top roller.

- Screw in thoroughly downwards the screw (2).

- Tighten slightly the screw (3) in such a way that the lever (4)

turns on the shaft (5) with a certain friction moment.

- Push with the screwdriver on the lever (4), until it attains

the wall inside the arm of the sewing machine. In this

position, tighten duly the screw (3).

- Check the axial clearance of the shaft (5) which should be

the least possible.

- Set the normal pressure force of the top roller.

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!

3.9 Bobbin winder

3.9.1 Description

The winder (bobbin winder) winds a reserve of the hook thread.

It is driven by a spring-mounted friction gear, which stops

after having filled the bobbin.

An ideal winding is attained with a sufficient pretension of the

thread obtained on the thread guide (4) and with 1 mm under the

diameter of the bobbin. The shaft is mounted in a swinging way

and the friction gear is put into engagement by means of a pickup

lever (1) and a cam. The winder is fixed on the machine arm by

two screws (3). The thread is passed through according to the

illustration, the thread is cut off after having stopped the winding

operation using the cutting device (5).

3.9.2 Setting the bobbin winder stop

The moment of interrupting the winding is determined by the

mutual position of the pickup lever (1) and the cam (5) on a

common shaft.

The cam is locked in its functional position by the screw (6). The

mutual position is to be set on a not incorporated winder in such

a way that in the moment, when the pickup lever leaves the space

of the bobbin, the pressing function of the cam on the winders

shaft is interrupted and it moves in the sense of the arrow. A fine

setting is to be done on an incorporated condition in the machine.

Using the screw (2), the position of the friction part of the pickup

lever (1) is adapted. In opening the lever, the stopping function is

accelerated. Its inverse function delays it. A test is to be done after

having inserted the bobbin, when passing the thread through the

device and when winding at the running of the machine.

3.9.3 Setting the friction gear

The friction gear is formed frontally by the disk (8) on the

main top shaft of the machine and by the disk (7) with a rubber

ring on the shaft of the winder.

Caution! Danger of injury!

Switch off the main switch! Before starting the setting

operation, wait until the motor stops!

- Proceed to the setting operation with a removed rear guard.

- The winder is in its stopped position.

- Loosen two screws (9) in the disk (8) through the hole in the

arm.

- By shifting axially the disk in the sense A, B, set the disks of the

winder (7) at the distance of 0.5 mm from the rubber ring.

- Tighten the screws (9) in the disk (8).

- Put the winder in its working position and proceed to a winding

test.

- Mount the rear guard.

3.10 Safety clutch

3.10.1 Description

The machine is provided with a safety clutch which enables

the turning through of the lower belt wheel (1) on the hub of

the lower shaft (2), when the hook is blocked. This blocking

occurs due to the penetration of thread into the hook path.

With current running, this clutch should not disengage during

the normal running. The mutual connection of the belt wheel

(1) with the hub is enabled by the pins (5) which fit with their

conic ends into the holes of the belt wheel. The pins are pushed

by the springs (4). Putting the clutch in its working position,

eventual checking its correct position are to be done in

blocking the hook using a screwdriver and in turning a bit the

handwheel.

3.10.2 Setting the disengaging moment

Caution! Danger of injury!

Switch off the main switch! Before starting the setting

operation, wait until the motor stops!

The moment of 8 to 9 Nm is correctly set, when the screwed in

adjusting screws (3) come to lie 0.5 to 1.5 mm under the face

of the hub (2). When the clutch disengages during a normal

run, the screws are to be turned by one thread to the right and

a test is to be done during the running. In an opposite case,

when the hook is blocked, but the clutch does not disengage,

the disengaging moment of the clutch is to be reduced in

turning the screws to the left.

Caution!

The clutch guarantees only one mutual position

of the hub of the lower shaft (2) and that of the

belt wheel (1). No checking according to the gauge

marks is needed. Putting the clutch out of operation by excessive

tightening of the screws (3) can cause, when blocking the hook,

the destruction of the gear within the drive of the hook.

3.11 Indented belt transmission

3.11.1 Setting the tensioning roller of the

indented belt

The optimum tension of the indented belt (1) is attained in

setting the tensioning roller (2) in such position, when the

roller applies the pressure of F = 20 N against the belt. The

roller must be side set in such a way that the edge of the

indented belt does not overlap over the edge of the roller.

Caution! Danger of injury!

Switch off the main switch! Before starting the setting

operation, wait until the motor stops!

- Remove the handwheel and the belt guard, remove the V-belt.

- Unlock the fastening of the loop, on which the roller (2)

is mounted in such a way that the loop turns freely.

- Lift the roller (2) upwards and, thereafter, using the dynamo-

meter (4), pull horizontally the roller in applying the force of

2O N. In this position, tighten the fastening screw (3).

- Check the side shifting of the roller.

432

3.11.2 Replacing the indented belt

To observe: in machines with Mini-stop first remove the driving

toothed belt as instructed in par. 3.13.

When replacing the indented belt, the mutual position of the

pulleys (4 and 5) should be maintained.

Caution! Danger of injury!

Switch off the main switch! Before starting the setting

operation, wait until the motor stops!

- Remove the handwheel, the belt guard and the V-belt.

- Remove the retaining ring (1) and remove the backtacking

lever (2).

- Mark with a pencil the instantaneous position of the

indented pulleys against the machine head in any position.

- Remove the indented belt (3) from the bottom indented pulley

(4) first, and then remove the whole belt.

- Apply a new indented belt on the top indented pulley (5) first.

- Turn both indented pulleys in the formerly marked positions

and apply the indented belt on the indented pulley (4).

- Tension the belt and mount the dismantled components in

the inverse order.

3.12 V-belt, motor - head

3.12.1 Tensioning

10 N

3 21

l - 20mm

10 N

Caution! Danger of injury!

Switch off the main switch! Before starting the setting

operation, wait until the motor stops!

The belt is correctly tensioned, when the opposite sides of the

belt approach one to another by up to 20 mm in applying the

force of 10 N. The belt is tensioned in turning respectively the

motor in its holder.

3.12.2 Replacing the V-Belt

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 positioner arrest (2) and tilt the

arrest.

- Unscrew the screws (3) of the handwheel.

- Unscrew the screws (4) of the belt guard and tilt the guard.

- Remove the belt guard of the motor and tilt the protections

against falling out the belt from the motor pulley.

- Replace the belt.

- Tension the belt (see par. 3.12.1).

3.13 Driving toothed belt

3.13.1 To exchange the driving toothed belt

Caution! Danger of injury!

Switch off the main switch! before starting the

setting operation, wait until the motor stops!

- Remove the machine head from the stand (uncouple the

motor cables, the machine head cable, the position sensor,

and screw off the wood screw and the screw from the hinges).

- Remove the belt guard (1).

- Replace the belt (2).

3.14 Lubrication

3.14.1 Description

In the main lubrication reservoir (1) there is a suction wick (2)

which wipes against the shaft (3). The wick (4) collects oil

from the shaft (3) and feeds it into the wick (5) which

distributes oil to the lubricated spots. The left branch lubricates

the needle and the thread mechanisms. The right branch

lubricates the mechanism of the stitch length and, thereafter,

pushed into the box (11). The wick (6) sucks off the excessive

oil from the needle and the thread mechanisms and also

pushed into the box (11). The lubrication reservoir (7) feeds

oil through the wicks (8) for lubricating the hooks. The wick

(9) lubricates the shifting wedge of the feed clutch. The wicks

(10) lubricates the gears of the hooks drives.

1110

543 2

3.14.2 Refilling oil

For lubricating the machine oil Esso SP-NK 10 is used or

other oil with the same quality. When putting the machine

into operation, each mechanism of the machine is to be

lubricated with several drops of oil. Oil is only refilled thereafter

into the oil reservoirs using an oil can into the holes in the oil

level indicators. The oil reservoir (1) is to be filled up to the

half of its content. The oil reservoir (2) is filled up to the pouring

holes.

3.14.3 Multiple oil use

Oil which runs into the oil cup is collected in the collector (1) and

may be reused for refilling the oil reservoirs in the machine - see

par. 3.1.4.2.

The oil collector (1) with the collected oil is uscrewed and the top

part of the oil can (2) which is added in the machine packing is

screwed in. Oil is then refilled into the reservoirs on the machine

head and everything is put into the original condition.

4. Thread trimming

4.1 Description of the trimming mechanism

11 10 865

During the trimming cycle, the moving trimming knife (1), in

an opportune moment, hooks up the sewing threads and pulls

them in the sense of the arrow (A) against the fixed knife (2)

until the threads are trimmed. The spring (3) holds the hook

thread after being trimmed off. The moving knife (1) is mounted

on the shaft (4) which turns by means of the lever (5) under

the effect of the fork (6) fixed on the shaft (7) which is shifted

by the electromagnet (8) from its starting position in the sense

of the arrow (B). When moving back in the sense of the arrow

(C), the shaft (7) is shifted by the cam (9) through the pickup

roller (10) into the starting position. The spring (11) maintains

the mechanism in its starting position. The electromagnet

(12), in an opportune moment, loosens the main tensioner

(13). At the end of the trimming cycle, both electromagnets (8

and 12) are switched off.

4.2 Setting the pickup roller

The holder of the pickup roller (1) is to be fixed in such a way that

it is positioned, in its starting position, between the shaft (2) and

the shaft (3), the respective gap A = 0.2 to O.4 mm.

Caution! Danger of injury!

Switch off the main switch! Before starting the setting

operation, wait until the motor stops!

- With the loosened screw (4), put the holder of the pickup

roller (1) up to the stop against the bracket (5) and, at the

same time, the shaft (2) up to the stop against the shaft

(3).

- With the holder (1) held on the stop, shift the shaft (2) in

such a way that there appears the gap A = 0.2 to 0.4 mm,

and tighten the screw (4).

- Check the gap A in shifting the armature (6).

4.3 Setting the cam

The position of the cam (1) against the shaft (2) is to be such,

so that when the adjusting pin is in contact with the shaft (4),

the protractor scale of the handwheel (6) shows just the angle

of 108°. If the pickup roller (5) is in its starting position of

rest, the clerarance between the roller (5) and the cam (1)

should be as small as possible but sufficient to prevent the

cam from getting into accidental contact with the roller.

Caution! Danger of injury!

Switch off the main switch! Before starting the setting

operation, wait until the motor stops!

513824

108

- Set the angle of 108° on the handwheel (6) and lock it with

the screw (7) which is included in the accessory of the

machine (tighten with care).

- Shift the pickup roller (5) in the sense of the arrow up to the

stop.

- Insert the adjusting pin (3), which is included in the acces-

sory, into the cam and turn the cam, until the pin (3) gets

the contact with the shaft (4).

- Insert a gauge having the thickness of 0.1 mm between the

cam (1) and the pickup roller (2) and shift the cam against

the gauge up to the stop. Tighten then the screw (8).

- Loosen the blocking of the handwheel, turn a bit the cam

and tighten the second fastening screw of the cam too.

563

4.4 Setting the fork

In the starting position of rest of the trimming mechanism,

when the holder (1) is in contact with the bracket (2), the axis

of the fork (3) must intersect the axis of the shaft (4).

Caution! Danger of injury!

Switch off the main switch! Before starting the setting

operation, wait until the motor stops!

- Shift the shaft (5), until the holder (1) strikes the bracket (2).

- Loosen the screw (6).

- Shift the fork (3) in such a way that its axis intersects the axis of

the shaft (4).

- Tighten the screw (6).

4.5 Setting the moving knife

The moving trimming knife (1) is to be placed in its starting

position at rest with its end at the distance of the measure

A= 0.1 to 0.5 mm from the edge of the fixed trimming knife (2).

The height setting is to be such that its top surface is 1.8 mm

below the top surface of the throat plate.

Caution! Danger of injury!

Switch off the main switch! Before starting the setting

operation, wait until the motor stops!

1/2

- Loosen the screws (4 and 5).

- Turn the moving trimming knife (1) in the sense of the arrow

and set it in height. Tighten the screw (5).

- Turn the moving trimming knife (1) into its starting position

in such a way that the measureA = 0.1 to 0.5 mm is

attained. Tighten the screw (4).

4.6 Setting the fixed knife

The fixed trimming knife (1) is to be tensed up by the screw

(2) in such a way that it bears on the moving trimming knife in

the 1/2 of its length. The knives need not to trim untensioned

threads.

Caution! Danger of injury!

Switch off the main switch. Before starting the setting

operation, wait until the motor stops!

1/2

- Set the angle of 300° on the handwheel (4).

- Shift by hand the moving knife (3) into the marked position.

- By turning the screw (2), try to set the tensing up of the fixed

trimming knife (1).

- Check the bearing spot of the moving trimming knife (3) on

the fixed trimming knife (1) and give it a correction, if needed.

300

0,8 mm

4.7 Setting the retaining spring of the hook thread

The retaining spring (1) holds the hook thread after having

performed the trimming. It is to be set in such a way that the

force necessary for pulling out the thread from the retaining

spring (1) is approximately equal to the force necessary for

pulling out the thread from the hook.

Caution! Danger of injury!

Switch off the main switch! Before starting the setting

operation, wait until the motor stops!

231

- Using the screw (3),set the height of the top edge of the

retaining spring (1) 1 mm below the top edge of the moving

trimming knife.

- Shape the retaining spring (1) in such a way that it fits close

with all its surface (without wedge) onto the moving trim-

ming knife (4).

- Shape the retaining spring in such a way that it fits close, with

the slightly tightened screw (2), onto the moving trimming

knife without any pressure.

- Tighten the screw (2), until the necessary force for pulling the

thread from the retaining spring is attained. The pulling force is

tested using a screwdriver according to the illustration.

Caution!

The setting of the retaining spring (1) depends on

the setting of the hook tension and differs then

according to the respective sewing category.

The adjusting screw (2) should not be screwed in in such a

way that the retaining spring gets over the perimeter of the

moving trimming knife.

4.8 Setting the switching of electromagnets

The electromagnets of the trimming device and loosening of the

tensioner must work in accordance with the diagram. This is

ensured by setting the stopmotor (see the instructions for

use of the stopmotor).

132

241

1- 1. position of the needle (225° on the handwheel)

/135o Mini-stop QE 3760/DA47MS/

2- 2. position of the needle (64° on the handwheel) 3- position of stopping the tensioner (10° ÷ 25° on the hand-

wheel)

4- movement of the pickup roller

5- current of the trimming device electromagnet

6- current of the tensioner loosening electromagnet

5. Lifting the top roller by electromagnet

5.1 Description

The core of the electromagnet, respectively its pin must be set in

such a way that the presser foot lifting is enabled.

5.2 Setting the electromagnet pin

Caution! Danger of injury!

Switch off the main switch! Before starting the

setting operation, wait until the motor stops!

- Unscrew the cap of the core (1) of the electromagnet.

- Shift the core (2) with the pin (3) and loosen the locking

screw (4).

- By screwing the pin (3) in the core (2), set their mutual

position in such a way that the core is fully pushed in with

the maximum presser foot lift.

- Tighten the locking screw (4).

- Screw on the cap (1).

5.3 Setting the electromagnet current

The time response of the current of electromag. has 2 phases:

- initial switching on (0,2 ÷ 0,5 s) - the maximum force

- maintaining (when keying)

It is necessary to set max. 40 % of keying (see instru-

ctions for use of the stopmotor). With a higher value

thereof and with a long period of the presser foot

in its lifted position there is a danger of electromagnet

overheating.

5.4 Aseembly of the top roller lifting

electromagnet

- Remove the rear guard (3).

- Using the screws (1), fasten the electromagnet (2) on the rear

guard (3) with the given orientation of the outlet cable (4).

- Mount the rear guard (3).

- Connect the outlet cable (see par.7).

- Set the pin of the electromaghet (see par. 5.2).

- Set the current of the electromagnet (see par.5.3).

Caution! Danger of injury!

Switch off the main switch! Before starting the setting

operation, wait until the motor stops!

6. Backtacking using electromagnet

6.1 Description

The position of the electromagnet with regard to the backtacking

lever must be set in such a way that it enables the maximum stitch

length when sewing in forward and in rearward sense. If this

position is not correct, the length of the stitch will be shortened in

one or the other feed direction.

6.2 Electromagnet height setting

Caution! Danger of injury!

Switch off the main switch! Before starting the setting

- Set the maximum stitch length.

- Set the position of the electromagnet (2) against the midpoint

of the grooves (1) of the guard (3).

- Mount the guard (3) on the head (the bar must have a clearance

between the stop on the backtacking lever and the extreme top

position at least of 0,5 mm).

- The backtacking lever (4) is to be shifted into its bottom position

(the bar (5) is to be in contact with the backtacking lever (4) ).

operation, wait until the motor stops!

6.3 Setting the position of push-buttons

Caution! Danger of injury!

Switch off the main switch! Before starting the

setting operation, wait until the motor stops!

- By loosening the screws (1), it is possible to set the height of

the push-button holder.

6.4 Change of the function of push-buttons

The Function of the push-buttons can be changed in accordance

with the possibilities given by the stopmotor (see instruction

for use of stopmotor).

456 7

7. Connecting the electric elements on the

machine head

The connection of the electric elements (electromagnets,

backtacking, presser foot lifting, thread trimming, loosening

of the tensioner and push-buttons) is made by means of a

switchboard (1) fixed with its supporting plate on the rear

side of the head by means of two distance screws (3) (In the

Fig., these electric elements are disconnected).

213

Connecting spots :

4 - backtacking electromagnet

5 - trimming electromagnet

6 - tensioner loosening electromagnet

7 - presser foot lifting electromagnet

8 - connector of push-button connecting

9 - connector of coupling the head with the stopmotor

10 - connecting cable of the head and stopmotor

Wiring diagram of connecting the electric elements of the

machine head.

8. Drive, control panel, position sensor

The detailed information concerning the drive, the control panel

and the setting of the position sensor is given in the manual of the

drive and of the control panel.

9. Lighting

9.1 Mounting on the machine head

- Mount the lamp on the machine head using the screws (3).

- The lighting (5) conductor is to be led through the guard (1)

into the channel of the head on its rear side.

9.2 Lamp replacement

- Remove the guard (1) by unscrewing the screw (2).

- Remove the lamp from the machine head by unscrewing two

screws (3).

- Shift the glass (4).

- Loosen two screws of the lamp holder.

- Replace the lamp.

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!

Use only 12 V, 10 W lamps. With higher values of

the lamp power, there is a danger of overheating.

10. Maintenance

Caution! Danger of injury!

The maintenance operations should be performed only with the machine switched off and with the motor stopped!

In the following table there are given the operations which should be performed and the respective time intervals between the

individual operations.

Operation Time interval

Removal of the throat plate and its cleaning out. Cleaning out of the wheel feeder, hook and their

surrounding space. Removal of the residues of material and threads from the top roller

Checking the oil level in oil reservoirs. 1 month

Checking the hook wear. Checking the function of the safety clutch against the hook overload. 6 months

Checking the V-belt and the indented belts, checking the friction wheels of the drive convertion unit. 1 year

. 1 day

11. Setting the machine according to the sewing category

11.1 Introduction

This sewing machine enables sewing operations within a large extent from 1. 2 to 3.2 mm the light up to the heavy-duty sewing.

The parameters of the respective sewing operation must be in accordance with the given machine setting which includes also the

replacement of some components, such as the needle, the throat plate insert, the spring of the main tensioner, the top roller. For

this reason, the setting of the machine is divided into 4 categories:

1 ... light sewing

2 ... medium sewing

3 ... medium heavy-duty sewing

4 ... heavy-duty sewing

In the factory, where this machine has been manufactured, it has been set up with respect to the standard parameters of the

required stitch width and the required sewing category which is designed by the number included in the commercial designation

of the machine. If the user desires changing the given setting to another sewing category or stitch width of needles, this

operation should be performed by a specialized mechanician.

Caution!

When changing the sewing category, loosen the tensing up of the fixed trimming knife.

Otherwise there is a danger of destruction of the moving knife.

The standard parameters of sewing are described in the following paragraph. The actual parameters of sewing inside the given sewing

category may be different, which means that the machine operative must adapt respectively the setting of the machine, e.g. the tension of

the upper thread.

11.2 Table of setting the machine according to the sewing category

Commercial designation of the machine 4260 - 6XX - X

Standard sewing parameters

Seam Thick- Number Stitch Label

dis- ness of length num-

tance of one material ber of

material layers thread

layer PES

Sewing category

mm mm mm

1,2 0,8 2 2 70

-100

1,6 1 2 2,5 40

-200

2 1,5 1-2 3,5 20

-300

2,4 2 1-2 4 10/20

-400

Setting as per Instructions for service 3.3.1 3.6.4.2.3 3.7.8.1 3.7.8.2 3.5.5

chapter

Instruction manual 6.5 6.3 6.3

Instruction for assembling

Needle Sewing Width Feeder Presser Presser Threads Thread Spring Dishs

size speed of - top top tension limiter of main of

7) hole 8) 6) 3)

0,01mm st/min. m m m m m m m m N N

80 2500 1,3 0,4 35 10,5 3 1 L

90 2000 1,6 0,4 35 10,5 4,5 1,5 M

130 1200 2,2 0,6 35 10,5 5 - 8 2 M - H

160 800 2,5 1,2 35 10,5 10- 12 2 - 2,5 H

2.4

4.5

Standard machine setting 1)

needle pitch roller roller

plate of teeth diameter position needle shuttle ne r ners

insert thread thread

tensio- tensio-

522 467 110 220 80522 080 828 102

522 099 004 800 80

1) The standard setting of the machine for the categories 3 and 4 concerns a decorative stitching, when it is difficult to match

a good stitch interlocking with a faultless function of the thread trimming device. Otherwise, when sewing material of

considerable overall thickness, it will be necessary to increase the overtopping of the teeth above the needle plate and to

increase also the needle thread tension.

2) The thickness of a layer is measured using an engineer slide calliper with the pressure of jaws of about 10 N.

3) One set of dish-shaped springs is mounted, another one is enclosed.

4) The values of tension are only orientative ones and it is necessary to adapt especially the tension of the shuttle thread

according to the stiffness of the material. An excessive tension of the threads when sewing soft materials causes material

wrinkling.

5) When performing decorative stitching of the category 4, the shuttle thread having the label No 20 is used.

6) When changing markedly the sewing category together with changing the tension of the shuttle thread, it is necessary to

modify the tension of the retaining spring of the trimming device according to the paragraph 4.7.

7) When changing markedly the sewing category together with a marked change of the needle number, it is necessary to correct

the setting of the distance of the shuttle from the needle, according to the paragraph 3.1.3 and, at the same time, the setting

of the fixed trimming knife of the trimming device, according to the par. 4.6.

8) There are in use various types of feeders with the purpose of avoiding imprinting the teeth in the lining leather. Otherwise, it

is possible to use any feeder.

11.3 Table of possible stitch widths of needles according to the sewing category

Sewing Distance of seams (stitch width) Maximum

category 1,2 1,6 2 2,4 3,2 stitch length

mm mm

- 100

Light

- 200

Medium

- 300

Medium heavy

- duty

- 400

Heavy - duty

(decorative)

•

Duerkopp Adler 4260 - 6 Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual