Page 1
Contents Page:
Part 3: Service Instructions Cl. 506
1. General
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2. Removing the Machine Head Cover and Tilting the Machine Head
2.1 Removing the Machine Head Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.2 Tilting the Machine Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3. Barrel Shuttle, Needle Bar
3.1 Needle Bar Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.2 Synchronizing the Hook and Needle Bar Movement . . . . . . . . . . . . . . . . . . . . . . . 8
3.3 Clearance Hook Point - Needle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.4 Clearance Driver - Needle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.5 Looping Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.6 Worm Wheel Play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4. Clamps and Feed Plate
4.1 Position of the Feed Plate to the Needle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4.2 Position of the Clamps to the Feed Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
5. Bobbin Ejector
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
6. Curve Disk
6.1 Replacing the Drive Train and Worm Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
6.2 Replacing the Curve Disk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
6.3 Installing the Gear Reducer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
7. Thread Pull
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
8. Thread Controller Spring
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
9. Needle Cooling
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
10. Shut Off Devices
10.1 Transport Levers for the Length and Crosswise Movement (Switches b09, b16) . . . . . . . 28
10.2 Base Position Stop (Switch b10) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
10.3 Synchronizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Page 2
Contents Page:
11. Thread Burning Device
11.1 Thread Deflector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
11.2 Upper Burning Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
11.2.1 Position of the Fully Extended Burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
11.2.2 Setting the Height Stop of the Burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
11.2.3 Angle Position of the Burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
11.3 Lower Burning Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
11.3.1 Prerequisite for the Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
11.3.2 Initial Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
11.3.3 Clearance between the Thread Puller and the Burner . . . . . . . . . . . . . . . . . . . . . . 40
11.3.4 Position of the Swung-forward Burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
11.3.5 Height of the Burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
11.3.6 Height of the Thread Puller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
12. V-belt Tension
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
13. Setting the Bobbin Winder
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
2
Page 3
1. General
These servic e i n s tru c ti o ns d es cr i b e t he s et ti n gs f or the sewing uni t i n
a practical o r de r.
Attention !
Various setting positions are interdependent.
It is therefore essential to make the settings while keeping to the order
described.
ATTENTION !
The tasks described in these service instructions may only be
conducted by skilled personnel or appropriately trained staff !
Danger of Breakage !
After disassembly work first conduct the required setting tasks as per
these service instructions before putting the sewing unit into service
again.
Never start the sewing unit with an incorrect direction of rotation of the
drive motor.
It is only possible to start a sewing sequence with closed head cover
and closed cov e r of th e h oo k are a.
If the head cover or the cover of the hook area is open all functions of
the controls a r e b l ock e d.
Caution Risk of Injury !
During repair, conversion an d m ai n te na nc e wo rk tu rn t he ma i n switch
off and disconnect the sewing unit from the pneumatic supply.
Adjustment work and function testing with the unit running are to be
conducted only observing all safety measures and with the greatest
possible cau ti o n.
For setting work in the area of the clamps and the needle these must
be removed bef ore hand in order to av o i d i n j uri e s .
Setting Gauges
Along with th e u s ua l pa r ts a nd tools the fol l ow i ng s et ti n g g au ge s are to
be found in the a c c es so r i es pack:
Setting Gauge Application
Gauge Setting the needle bar height,
synchronizing the hook and
needle bar movement
Timing pin Synchronizing the hook a nd
needle bar movement
On request you c an al so receive the fo l l ow i ng s et ti n g g au ge s :
Setting Gauge Application Order no.
Gauge Se tt i ng th e l o op i ng s tro k e 981 150012
Block Setting the l o op i ng s tr o ke 981 150006
3
Page 4
2. Removing the Machine Head Cover and Tilting the Machine Head
2.1 Removing the Machine Head Cover
For service work on the inside of the machine head the machine head
cover 2 is to be removed.
For this the Microcontrol control unit must first be swung to the side.
Caution Risk of Injury !
Turn the main switch off.
Remove the machine head cover only with the main switch turned off.
Swing the Microcontrol control unit to the side
–
Slightly loosen the Allen screws 1.
The Allen sc re w s ar e ac ces s a bl e thr o ug h th e ho l es 3 i n th e c ov e r.
–
Carefully swi ng th e M i cr oco nt r ol co nt r ol u ni t to th e s i d e.
–
The machine head cover 2 is freely accessable and can be
removed.
Remove the bobbin winder
–
Loosen the mounting srews of the bobbin winder and remove the
bobbin winder.
Remove the machine h e ad c ove r
–
Loosen the mounting screws of the machine head cover 2.
–
Carefully lift the machine head cover 2.
–
For the complete removal of the machine head cover loosen the
screws 4 of the compressed air hose.
ATTENTION !
Removing the machine head cover by force can lead to damage to the
compressed air feed.
1
2 3
4 2
4
Page 5
2.2 Tilting th e Machin e Head
For service w or k o n the underside of th e m ac h i ne he ad th i s must be
tilted to the b ack .
Caution Risk of Injury !
Turn the main switch off.
Tilt the machine head only with the main switch turned off.
–
Swing the V-belt cover 1 to the back.
–
Carefully ti l t th e m ac h i ne he ad ov e r an d l a y onto the support on
the table.
The underside of th e m ac h i ne he ad i s ac ce s s ab l e f or s e r v ic e w or k .
1
5
Page 6
3. Barrel Shuttle, Needle Bar
ATTENTION !
The settings d es c ri b ed i n t he Chapters 3.1 to 3 .4 ar e i nt erd ep endent.
It is therefore essential that the individual settings be made in the
order listed in the service instructions.
3.1 Needle Bar Height
When the hook point extends 2 mm beyond the right needle side
the eye of the needle must be under the hook point.
Caution Risk of Injury !
Turn the main switch off.
Adjust the needle bar height only with the main switch turned off.
–
Switch off the main switch.
–
Loosen screws 2.
–
Remove the clam ps 3 .
Caution Danger of Breakage !
Before conducting the following settings it is essential to remove the
clamps. This a voi d s th e n ee dl e hi t ti n g a ga i ns t th e c l am ps du ri ng the
settings following later.
2
3
6
Page 7
–
Turn the handwheel i n t he di r e c tion of run until th e h oo k po i nt
exceeds the ri g ht ed ge of the needle by 2 mm .
ATTENTION!
Care of the driver lying on the barrel shuttle in the direction of run.
–
Loosen the cl a mp i ng sc r ew s 4.
–
Set needle bar he i ght s o th at th e l o we r ed ge of th e h oo k j ust
becomes visi b l e in the eye of the ne edle (see drawi ng ab ov e ) .
–
Tighten the clamping screws 4.
–
Attach again clamps 3 with screws 2.
4
2 mm
7
Page 8
3.2 Synchronizing the Hook and Needle Bar Movement
The synchronization of the hook movement to the movement of the
needle bar is m ad e with gauge 1 and timing pin 3.
Caution Risk of Injury !
Turn the main switch off.
Synchroniz e t he ho ok a nd ne ed l e b ar m ove ment only with t he ma i n
switch turned off.
–
Insert the timing pin 3 into the hole in the housing on the machine head.
–
Turn the handwheel in the direction of run until the timing pin 3 can
be felt to hav e c a ug ht i n t he gr o ov e on th e a r m sh aft crank.
–
Tilt the machine head to the side.
–
Insert gauge 1 th rough the hole in t he ho us i n g.
With a correct setting it must be possible to push gauge 1 into the
recess on the crank 2.
To correct:
–
Remove the machine head cover.
–
Loosen the cl am pi n g sc r e ws 5 on th e t i mi n g b el t pu l l ey 4 .
–
Turn the handwheel in the direction of run until the gauge 1 can be
pushed into the recess on the crank 2.
–
Tighten the clampin g s cr e ws 5 .
–
Replace the machine head cover again.
1
2
3
4
5
8
Page 9
3.3 Clearance Hook Point - Needle
The hook point 8 must lie as close as possible to the furrow of the
needle without touching it.
Caution Risk of Injury !
Turn the main switch off.
Set the clearance hook point - needle only with the main switch
turned off.
–
By turning the handwheel bring the hook point 8 to the the needle
and check the position of the hook point to the furrow of the needle.
To correct:
–
Tilt the machine he ad to th e s i d e.
–
Loosen the cl a mp i ng sc r ew s 7.
–
Loosen the clamping screws 2 on the set collar 6.
–
Remove driver with driver shaft 9 forward from shuttle run
bearing 3.
–
Loosen clam ping screw 5 on th e t he ba s e p l at e.
–
Screw in forcing screw 4 slightly.
The jaws on the base plate are spread.
–
Move the hook point 8 to the furrow of the needle by axial
relocation of the shuttle run be ari n g 3 .
The upper surf ac e of th e s h ut tl e run bearing 3 must t he reb y be
parallel to the needle plate.
–
Screw the forcing screw 4 back.
–
Tighten the clamping screw 5.
–
Re-insert dr i ve r wi t h d r iv er shaft 9 into shut tl e r un be ari n g 3 and
push it back.
–
Push the set collar 6 up to the stop against bushing 1.
–
Tighten clamping screws 2.
–
Tighten clamping screws 7.
ATTENTION !
When inserti ng a t hi c k e r ne edle the clearan c e o f t he hook point to t he
needle also ch anges automatic a l ly.
The clearanc e h oo k po int-needle is to b e c o r rec t ed .
3
4
5
1
6
2
9
7
8
A
A
A-A
9
Page 10
3.4 Clearance Dr iver - Needle
The encompassing driver 3 moves the barrel shuttle 1 in the shuttle
run.
With a correct setting of the dr i v e r th i s al so s er ves as a guide fo r th e
needle in the v e rti c a l di re c ti o n.
Missing stitches because of "shimmy" of the needle are avoided in this
manner.
The right side of the needle must touch the driver 3 without being
deflected.
For this the driver 3 must be set close to the the needle.
Caution Risk of Injury!
Turn the main switch off.
Set the cleara nc e dr i ve r - ne ed l e o nly with the main s wi t c h t urned off.
–
By turning the handwheel brin g t he ne ed l e i n to th e h i gh po s i tio n
(Position 2).
–
Pull the spring lock 4 forward for unlocking of the shuttle run
spring 5.
–
Swing the shu tt l e r u n s p ri ng 5 t o the back.
–
Remove the cover ring 2.
–
Take out the barrel sh ut tl e 1.
–
To check the the sett i ng mo v e t he dri v e r 3 t o t he ne ed l e b y tu rni n g
the handwheel .
3
2
1
3 4 5
10
Page 11
To correct:
–
Tilt the machine he ad to th e s i d e.
–
Loosen the clamping screws 11.
–
Loosen the clamping screws 7 on the set collar 9.
–
Pull the driv er 3 wit h t he dr iv e r sha ft 10 fo r wa rd o ut of th e s h ut tl e
run bearing 8.
–
Washers 12 to be adde d t o or removed from th e removed driver
shaft 10. You may find them in the accessories pack.
Remark
If using a thinner needle, sometimes it may be nessary to add a
washer and if using a thicker needle, to remove one.
–
Insert the dri v e r 3 w i th th e d r iv er shaft 10 into the s h ut tl e r un
bearing 8 agai n an d p us h to th e b ac k u p to the stop.
–
Push the set collar 9 up to the stop against the bushing 6.
–
Tighten the clamping screws 7.
The driver 3 is s e cur e d a ga i ns t ax i a l di s p l ac e me nt .
–
Reset the looping stroke (see section 3.5)
–
Check the setting by turning the belt pulley on the arm shaft. The
right side of t he needle must to uc h th e d r iv er w i th ou t b ei n g
deflected.
If the setting i s no t c o rr ect, repeat the pr ocedure.
ATTENTION !
After the setting of the clearance driver - needle it is essential to reset
the looping stroke per Chapter 3.5.
67
89 1011
12
10
11
Page 12
3.5 Looping Stroke
The looping st r ok e i s th e p ath of the needl e b ar f r om i ts lower dead
center up to th e p oi n t w he r e t he ho ok p oi n t 7 en ds w i th th e r i g ht
needle side.
The looping stroke must be 5 mm.
It is set with gauge 1 (Order no. 981 150012) and block 2
(Order no. 981 15 00 06 ).
Caution Risk of Injury !
Turn the main switch off.
Set the looping stroke only w ith the main switch turned off.
–
By turning the handwheel brin g t he ne ed l e b ar 4 into its low es t
position.
–
Open the head cover.
–
Press gauge 1 with block 2 upward against t he ho us ing.
–
Set the clamp i ng s cr ew 3 t i gh t t o the block 2.
–
Pull out gaug e 1 .
–
Turn the handwheel in the direction of run until the block 2 touchs
on the housin g.
–
Check if the h oo k po int 7 ends at the ri g ht ne ed l e s ide.
To correct:
–
Tilt the machine head to the side.
–
Loosen the clamping screws 6.
–
Turn the driver shaf t 5 ap pro pr i a te l y.
–
Tighten the clampin g s cr e ws 6 .
–
Check the clea r an c e d ri v er - n ee dl e ag ai n an d, i f n ec e s s ary,
correct (see Ch ap te r 3. 4).
1
2
3
4
56
7
12
Page 13
3.6 Worm Wheel Play
The tooth play between worm 2 and worm wheel 3 must as little as
possible.
Caution Risk of Injury !
Turn the main switch off.
Set the worm whee l pl a y on ly wi t h t he ma in s w i tc h tu rne d o ff.
To check:
–
Turn the curve disk to the right and left.
A little play must be felt.
To correct:
–
Remove the machine head cover.
–
Loosen the cl a mp i ng sc r ew s 1.
–
Set the tooth p l ay b y ax ia l rel o c at ion of the conical wo rm 2 on th e
arm shaft 4.
Attention !
The first screw - seen in the direction of rotation - must lie on the
surface of th e a rm s h af t.
–
Tighten the clamping screws 1.
–
Replace the m ac h i ne he ad c ov e r ag ai n .
12 3 4
13
Page 14
4. Clamps and Feed Plate
4.1 Position of the Fee d Plate to the Ne edle
The transmission of the movement from the curve disk to the
clamps and the feed plate occurs via lever systems.
By changing the lever multiplication the seam formation sizes can be
changed within certain limits.
The size of the safety clearance between the feed plate 1 and
the needle is de te rmi n ed by t he wi d th of the movement of the feed
plate in the crosswise and lengthwise directions.
For safety reasons the feed plate 1 must keep a uniform minimum
clearance to the penetrating needle over the whole course of the
bartack.
Attention Danger of Breakage !
Through not kee pi n g t he safety clear an c e t he pe ne tr a ti n g n ee dl e
strikes the feed plate 1.
Caution Risk of Injury!
Turn the main switch off.
Set the safety c le ar a nc e of th e f ee d plate 1 to the pen etrating needl e
only with the main switch turned off.
–
Loosen nut 3 and s c rews 2.
–
Pull off the curve disk 4.
–
Remove the claw from the curve disk.
–
Place the curve disk without the claw on the shaft again.
–
Turn the curve disk in the direction of run and run through the
complete bartack course.
Thereby chec k f or a un i fo r m safety clearanc e of th e f ee d plate 1 to
the penetrating needle.
–
For correcti on ti lt the machine he ad to th e s i d e.
1
34
2
14
Page 15
Align the feed plate 1 centered to the needle:
In the crosswise direction (Querrichtung):
–
Loosen the nuts 5 and 7.
–
By turning th e threaded rod 6 a li gn th e feed plate 1 in t he
crosswise direction centered to the needle.
–
Tighten the nuts 5 and 7.
In the lengthwis e di re c ti o n (L än gs ri c h tu ng ):
–
Loosen screw 9 s l i g ht l y.
–
By turning the eccentric 10 align the feed plate 1 in the lengthwise
direction ce nt er e d t o t he ne ed l e.
–
Tighten screw 9.
Setting the width of the movement of the feed plate 1:
In the crosswi s e di re c ti o n ( L än gs ri c h tu ng ):
–
Loosen the nut 8 s l i g ht l y.
–
Set the width of the movement in the crosswise direction by sliding
the link in the slot.
–
Tighten nut 8.
In the lengthwis e di re c ti o n (Q u erri c h tu ng ):
–
Loosen screw 9.
–
Set the width of the movement in the lengthwise direction by
sliding the link in the slot.
Attention !
Thereby do not c h an ge th e s e tt i ng of th e eccentric 10.
–
Tighten screw 9.
56 7 8
9 10
1
15
Page 16
4.2 Position of the Clamps to the Feed P late
The clamps 2 must be aligned congruent to the recess 1 in the
feed plate 3.
Caution Risk of Injury !
Turn the main switch off.
Align the clamps only with the main switch turned off.
–
Loosen the screws 5 on the clamp bracket 4 slightly.
–
By sliding t he c l am p b rac k e t 4 al i g n t he c l am ps 1 and 2 congruen t
to the recess in the feed plate 3.
–
Tighten screws 5.
12 3
45
16
Page 17
5. Bobbin Ejector
The ejector 4 must reliably eject the bobbin. The tip of the ejector
must not protrude into the bobbin’s range of movement.
Caution Risk of Injury !
Turn the main switch off.
Setting of the ejector only with the main switch turned off.
–
Tilt the machine he ad to th e s i d e.
–
Undo screw 1.
–
Rotate the ejector 4 on its axle in such a way as to ensure that the
bobbin is rel i ab l y ej e c te d when the lever 3 is o pe r at ed .
–
Tighten screw 1.
–
Operate the e j ect or l e v er 3 to en s ur e th at i t i s w ork i n g p r op erl y.
The bobbin capsule must swivel out automatically.
–
Undo the lock nut on screw 2.
–
Turn screw 2 to ad just the limit position.
The tip of the ejector must not protrude into the bobbin’s range of
movement.
–
Securely tighten the lock nut on screw 2.
–
Undo the lock nut on screw 5.
–
Turn screw 5 to ad just the limit position.
The ejector must reliably eject the bobbin.
–
Securely tighten the lock nut on screw 2.
5
2
31
4
5
1
2
3
17
Page 18
6. Curve Disk
The curve runs on th e i n - an d o ut s i de of th e c u rv e d i s k determine the
transport movement of the clamps.
The outer curve run controls the movement of the clamps in the
crosswise di rec t i on, the inner transpo rts t he c lam ps i n th e l e ng th wis e
direction.
The position of the curve disk on the shaft determines the timing of the
clamp transpo r t.
The curve disk is in its base position when cam 1 is exactly in front of
switch
b10
.
In the base position of the curve disk the valve for the needle cooling
is not trigger e d. T he ne ed l e cooling is only ac t i vated during sewing.
Curve disk
The different seam formations (stitch patterns) are determined by
easily exchangeable curve disks.
All curve disks belonging to a stitch number range are
interchangeable with each other.
The curve disks are numbered.
The number engraved on the curve disk has the following meaning:
Example:
116 - 072 .- 1
116
= Number of stitches per curve disk revolution
072
= Stitch pattern
1= Calculation operation
Caution
The correct stitch number must be set with the DIP switches of the
micro-control (see chapter 2.2 in part 4: Programming Instructions).
Otherwise an incorrect seam pattern may result, or damage may be
caused to the needle or needle plate.
When converting to a different seam formation attach the clamps
belonging to t he mo unted curve dis k .
b10 1
18
Page 19
Worm wheel set
For conversion to a curve disk 4 of a different stitch number range the
appropriate
worm wheel set
must also be mounted. A worm wheel set
consists of a worm driver 2 and a worm 3.
Gear reducer
Through insta l l at i on of th e g ea r red uc e r 6 w i th th e i n te r me di a te ge ar 5
the number of stitches per curve disk revolution is doubled
(multiplication ratio 1:2).
Without gear reducer: 42, 58 and 72 stitches per curve disk
revolution (depending on the worm wheel set)
With gear redu c er: 84, 116 and 144 stitches p er c u rv e d i s k
revolution (depending on the worm wheel set)
56
23 4
19
Page 20
6.1 Replacing the Drive T rain and W orm Wheel
Caution Risk of Injury !
Turn the main switch off.
Replace the drive train and worm wheel only with the main switch
turned off.
Attention Danger of Breakage !
Before replacing the drive train and worm wheel it is essential to
remove the clamps and needle.
–
Remove the clam ps a nd ne ed l e.
–
Swing the V-belt cover 8 to the back.
–
Loosen the cl am pi n g sc r e ws 2 on th e s y n chr o ni z e r r i ng .
–
Pull off the synchronizer 1.
–
Flip up the securing clip 5 and pull off the plug 6.
–
Remove the cove r 3 a ft er lo os e ni n g t he mo un tin g s c re ws .
–
Pull the V-belt 7 off of the belt pulley.
Thereby slightly tilt the machine head in order to relieve the
V-b elt 7.
–
Swing the Mic rocontrol contr o l un i t o ver t o t he s i de an d r e mo v e t he
machine head c ove r (s ee Ch ap te r 2) .
–
Loosen the clamping screws 10 on the worm 11.
–
To pull out the drive train, first push the worm 11 to the back in the
direction of the arrow.
1 2 3 4
5 6 7 8 9
11
10
20
Page 21
–
Loosen the screws 4 on the bearing 9 and screw out.
The mounting sc r e ws 4 s erv e at th e s a me ti m e a s pu l l -off s c rews
for the drive t r ain.
–
Insert the s cr ew s 4 i n th e t hr e ad ed ho l es o f t he be ar i n g 9 .
–
Carefully pull the drive t r ain out of the housi n g b y un i fo r ml y
screwing in t he pu l l - off s cr ew s .
–
Loosen the cl a mp i ng sc r ew s 12 .
–
Pull the handwheel 13 with the belt pulley off of the arm shaft.
–
Loosen the cl a mp i ng sc r ew s 15 on th e b ea r i ng sl ee v e 1 8.
The clamping screws 15 are accessable through the slot 16.
–
Loosen the screws 14 on the bearing 17 and screw out.
The mounting sc r e ws 4 s erv e at th e s a me ti m e a s pu l l -off s c rews
for the bearing.
–
Insert the screws 14 into the threaded holes 18.
–
Carefully pull the complete bearing 17 ou t o f t he ho us i n g t hr o ug h a
uniform scre wi n g i n of th e p ul l -o ff sc rews.
–
Loosen the cl a mp i ng sc r ew s 20 on th e t i mi n g b el t pu l l ey 2 1.
–
Pull the timing belt pulley 21 off of the arm shaft.
–
Pull the wor m 11 off of the arm shaf t.
–
Push a new worm on to th e a rm s h af t.
–
Successively mount and fasten the timing belt pulley 21, bearing
17 and handwheel 13 again.
–
Mount the new drive train and fasten with the screws 4.
–
Push the worm 11 over the worm wheel and set the worm wheel
play (see Chapte r 3. 6).
–
Attach all parts removed (V-belt 7, cover 3, plug 6, synchronizer 1
and V-belt cover 8) agai n .
12
13
14
15
16
17
18 19
20
21
11
21
Page 22
6.2 Replacing the Cur ve Disk
Caution Risk of Injury !
Turn the main switch off.
Replace the curv e di sk o nl y with the main swi t c h t urn ed off.
–
Loosen the sc rews 4.
–
Lift the drive lever 5 for the clamp crosswise movement and push
to the side.
–
Loosen nut 2 and s c rews 6.
–
Carefully pull off the curve disk 1.
ATTENTION !
If for the conversion to a differ en t s e am fo r ma ti o n t he at ta c hi n g o f t he
gear reducer is necessary this must occur before the installation of the
new curve disk . Fo r th e a tt ach i ng of th e g ea r r ed uce r see Ch ap te r 6. 3.
–
Installing a new curve disk.
Attention!
Take care that drive lever 3 for th e clamp lengthwise movement
catches in the inner curve run of the curve disk.
The claw 8 must encompass the surfaces 7 of the shaft.
Note:
The illustration shows a unit with attached gear reducer.
–
Turn the curve disk i n t he di r e c ti o n o f ru n until the cla w 8 i s felt to
encompass the surfaces 7.
–
Tighten nut 2.
–
Insert the clamps and needle.
–
Turn the curve disk farther in the direction of run until the cam 9
lies vertically above the shaft 11.
78
1
2
34 5 6
22
Page 23
–
Turn the handwheel i n t he di r e c tion of run until th e c la mps not
longer move.
With a correct setting the ne ed l e i s a t t hi s m om en t j u s t s h ort of
penetrating i n to th e m at er i a l.
To correct:
–
Turn the curve disk farther in the direction of rotation until the
cam 9 lies vertically above the shaft 11.
–
Loosen screw 14 on the rider 10 sl i g ht l y.
–
Push the ride r 10 wi t h sc re w 1 3 u nt il i t t ou che s on th e c a m 9 of th e
curve disk.
–
Tighten screw 14.
The position of the curve disk is fixed.
–
Loosen nut 2.
–
Turn the handwheel in the direction of rotation until the needle is
just short of entering into the material.
–
In this posi t i on pre s s cl aw 8 with a screw d ri v er through the sl ot 12
onto the surfa c es 7 of the shaft.
–
Tighten screws 6 and nut 2.
–
Push the ride r 10 ba c k al l t he wa y to th e r i g ht .
Attention Danger of Breakage !
After replacing the curve disk it is essential to check the following
settings:
–
Position of the feed plate to the needle (see Chapter 4.1)
–
Position of t he cl am ps t o t he fe ed pl a te (s ee Ch ap te r 4. 2)
9 10
11 12
13 14
910
23
Page 24
6.3 Attaching the Gear R educer
By attaching t he ge ar r e du cer 4 with intermediate ge ar 1 th e n um be r of
stitches per c urv e di s k r e v ol u tion is doubled (m ul t i pl i cation ratio 1: 2).
The attachin g o f t he ge ar re du c er m ust occur before t he i ns t al l a tion of
the new curve disk.
Caution Risk of Injury !
Turn the main switch off.
Attach the gear reducer only with the main switch turned off.
–
Remove the curve di s k a s de sc r ibe d i n Ch ap te r 6. 2.
–
From the outside fa sten the gear reducer 4 with screws 3 on the
machine arm.
–
Insert the bearing bracket 2 and set the intermediate gear 1 close.
–
First tighten screws 5 just a little.
–
Set the intermediate gear 1 completely tight by tightening screw 4.
ATTENTION !
Possibly existing tooth play will be increased by the multiplication of the
gear reducer. Therefore set the intermediate gear 1 completely tight.
–
Tighten screws 5.
–
Mount the curve dis k a s de s c ri be d in Ch ap te r 6. 2.
56
3
4
1
2
24
Page 25
7. Thread Pull
For a secure sewing on at the seam beginning a certain quantity of
drawn-forward needle thread is required.
The drawing-forward occurs after completion of the seam with the
clamps still lowered.
Function sequence
–
The needle thread tension opens.
–
The burner lowers.
–
The thread pu ll 1 p ul l s t he r eq uir e d t hr e ad qu an ti t y fo r wa rd.
–
The thread pu ll 1 m ov e s ba c k i nt o i t s ba s e p os i t i on .
–
The needle thread tension closes again.
–
The thread de flector pulls th e d r aw n-forward needl e t hre ad into the
burning posit i on .
–
The thread is bu r ne d o ff.
–
A new sewing sequence can be started.
Setting
The thread pull 1 must be set so that, depending on the material to be
worked, a secur e se am be gi n ni n g is a s sur e d.
ATTENTION !
If the drawn-forward thread quantity is too small the thread is too taut
during burning. The thread end doesn’t "melt together".
To correct:
–
Set the drawn - fo rw a rd thread quantit y by turning the st op pe r
screw 2.
The stopper screw 2 limits the stroke of the cylinder 3.
2
1
3
25
Page 26
8. Thread Controller Spring
Spring path
When the needle enters into the material the thread controller spring 1
must lay onto th e t hr e ad te ns io n c a r ri er 6 .
When the eye of the needle enters into the material the spring is just
then relaxed.
To correct:
–
Loosen clamp ing screw 5.
The clamping s c rew 5 is behind th e t hr e ad ret ur n r oll e r 2 u nd er t he
machine arm.
–
Turn the thread tension carrier 6.
–
Tighten clamping s cr ew 5.
Spring tension
The spring must hold the drawn-forward thread taut until the eye of the
needle enters in to the material .
The necessary s pri n g t en s ion i s de pe nd en t o n t he ma te r i al t o b e s e wn .
To correct:
–
Remove the securing collar 3 and washer.
–
Pull off the thread return roller 2.
–
Loosen screw 4 slightly.
–
Secure screw 4 against turning with a screw sdriver.
–
Set the spring tension by turni n g t he k nu r led nut 7.
Turning clockwise = Increase spring tension
Turning counterclockw ise = Decrease spring tension
–
Hold the knurled nut 7 and tighten screw 4.
–
Attach the thread return roller 2 again.
–
Attach the washer and securing collar 3.
6
7
2 3 4 5
1
26
Page 27
9. Needle Cooling
The needle cool i n g c a n b e s w i tc h ed fr o m n orm al t o c o nt i nu ou s
operation. The desired mode of operation is s e t a t th e DIP switch
b500.6 on the co nt r ol u ni t (s ee pa r t 4 : S h or t De s cr i pt i on Mi cr o c on trol).
In normal opera ti o n n eedle cooling i s on l y activated during s ew i ng .
The air current coming from nozzle 3 must be directed at the
needle in sufficient strength.
To test the needle cooling in normal operation select program P45:
–
Set the "
Program
" switch to "45".
–
Press the "
STOP
" key.
The program is activated.
–
In the right half of the second display line "
B-TEST->
Σ" appears.
–
Press the "Σ" key.
–
The unit slowly sews to th e se am end.
The needle cool i n g i s i n op era ti o n.
–
Check the strength and direction of the air current.
To correct:
–
Loosen clamping screw 2 slightly.
–
Align the no z zl e 3 to the needle.
ATTENTION !
The air current coming from nozzle 3 should in no case blow out the
burner.
–
Tighten clamping screw 2.
–
Regulate the strength of the air current with the adjustment
screw 1 of the throttle valve.
1
2
3
27
Page 28
10. Shut Off Devices
10.1 Transport Levers for Lengthwi se and Crosswise Movement (Switches b09, b16)
The setting of the switches
b09
and
b16
is only necessary by units
with an "
open guide curve
".
"
Open guide curves
" are used for seam formations where the seam
end and seam beginning are at different positions.
Through the str a i gh t s e c tion 1 of the curve r u ns t he tr a nsport levers fo r
the lengthwise an d c ro s sw is e mo v em ent a r e m ove d b ac k in to th e
initial position after completion of the seam.
The movement occurs in the base position of the curve disk via the
pneumatic cyl i n de r s 2 a nd 3.
The base position (seam beginning position) of both transport levers is
scanned via switches
b09
and
b16
.
1
2
3
28
Page 29
For setting bring the curve disk into the base position (seam beginning
position) and tilt the machine head back.
The setting of the switches b09 and b16 occurs in program
P63
:
–
Set the "
Program
" switch to "63".
–
Press the "
STOP
" key.
The program is activated.
The display shows "B?".
Setting switch b09:
–
Set the "
Program
" switch to "09".
The display shows the switching status (e.g. "
-B09
").
–
Loosen the cl a mp i ng sc r ew on th e s e t c o l l ar 5 s l i gh tl y.
–
Slide the set collar 5 on axle 6 until the display shows the
switching status "
+B09
".
–
Tighten the clampi ng s c rew on the set collar 5 .
Setting switch b16:
–
Set the "
Program
" switch to "16".
The display shows the switching status (e.g. "
-B16
").
–
Loosen the cl a mp i ng sc r ew s 4 s li g ht l y.
–
Slide switch
b16
sideways until the display shows the switching
status "
+B16
".
–
Tighten the clamping screws 4.
b09
b16
4
56
29
Page 30
10.2 Base Position Stop (Switch b10)
To every curve disk (number of stitches) belongs a cam 2 with a
certain diameter.
The diameter is sized so that the switch
b10
is no longer o pe r at ed by
the cam a stitch before or after the base position.
If the cam is re pl a c ed by a l arg er d i am et er ca m ( e .g . b ec a us e i t w as
lost or damaged) the following problem can arise:
When turning the unit on switch
b10
is operated, the curve disk,
however, lies a stitch be fo r e o r be hi n d t he ba s e p os ition.
Hereby the controls do not show an error message!
ATTENTION !
Only the cam 2 b el o ng i ng to th e c u r v e d is k or a cam of the same
diameter may be use d.
The cam may onl y be s o w i de th at s wi t c h
b10
is no longer o pe r at ed a
stitch before or after the base position.
Before setting the switch
b10
the setting of the synchronizer must first
be checked (see Ch ap te r 12 ) .
During the refe ren c e ru n t he fo l l ow ing c on di t ion s ap pl y f or t he
positioning i n th e base position:
–
The sewing dri v e run s un ti l c a m 2 tri g ge r s sw itch
b10
.
–
After reachi ng th e 1 s t p os i t i on th e s e wing drive stops i n p os ition 2.
If the display shows the error message "
GRUNDST
" the curve disk lies
a stitch too far.
The switch
b10
must be reset.
1
b10 2
30
Page 31
Setting switch b10
–
Loosen screw s 1 s l ightly.
–
Slide switch
b10
upward so that cam 2 reaches the switch sooner.
–
Tighten screws 1.
The outgoing f l an k of th e 1 s t p osi t i on ma y no t l i e to ge th er w i th th e
incoming flank of switch
b10
.
–
Set switch
b10
to cam 2 as described above.
–
Check position 1 (thread lever low position) of the synchronizer
(see Chapter 10 .5 ).
–
If necessary re-adjust switch
b10
.
31
Page 32
10.3 Synchronizer
The sewing un i t p osi t i on s i n t wo di ffer e nt po s i ti o ns :
Position 1: Thread lever low position
Position 2: Thread lever high position
The individu al p os itions are dete rmi n ed by t he po s i ti o n o f
corresponding light stops in the synchronizer.
Positioning i s no r ma l ly ad j us t ed at th e f ac t or y.
Caution Risk of Injury !
Before corre cti n g e ac h of the positions 1 through 2 turn t he ma i n
switch off.
Position 2 (thread lever high position):
–
Turn the main switch off.
–
Turn the handwheel to bring the thread lever into a central position.
–
Turn the main switch on.
The unit assu me s po s i ti o n 2 (th r ea d l e v er h i gh po s i ti o n).
–
Check the position of the thread lever, correcting it,if necessary.
To correct:
–
Loosen the cl am pi n g sc r e ws 3 on th e s y n chr o ni z e r r i ng 1.
–
Hold the synchronizer ring 1 in position.
–
Turn the handwheel to bring the thread lever to top dead center.
–
Tighten the clampin g s cr e ws 3 .
4
5
6
7
8
1
2
3
32
Page 33
Position 1 (thread lever low position)
–
Set the "
Program
" switch to "67".
–
Press the "
STOP
" key.
The program is activated.
The display shows "
N-TEST->
Σ".
–
Press the "Σ" key.
–
Select the rp m o f t he sew i ng dr iv e wi t h t he "
Program
" switch.
–
Press the "Σ" key.
The sewing dri v e run s at th e s e l ec t ed r pm .
–
Release the " Σ" key.
The sewing un i t p osi t i on s i n p os i t i on 1 (t hr e ad l ev e r l ow position).
–
Check the pos i t i on of th e t hr e ad l ever.
If necessary, correct the positioning.
To correct:
–
Remove the cover 2 of the synchronizer.
–
Loosen clamping screw 6.
–
Turn the light stops 4 and 5 so that their light slits are offset 180°,
that is, lie acr o s s fr o m e ac h ot he r.
–
Tighten clamping screw 6.
33
Page 34
11 . Thread Burning Device
The electric thread burning device separates the needle and
underthread b y bu r ni n g.
The needle thre ad is melted at t he en d.
The resulting small hardening hinders an unravelling of the seam.
To achieve a flawless melting of the thread ends only
synthetic
threads may be used.
The length of t he bu r nt - off un de rt h rea d o n the material co r res p on ds t o
the needle plate thickness of approx. 5 mm.
11.1 Thr ead Deflector
The thread def lec t or 3 pu l l s the thread quanti t y dra w n -fo r wa r d b y th e
thread pull into the correct position for the burning procedure.
Swing movement
The thread deflector 3 must pull forward as much thread as possible.
The drawn-for wa r d t hread quantity ma y, however, only be so gr ea t t ha t
the thread is not under tension.
ATTENTION !
Too hig h a te ns ion leads to a fr ayi n g o f the thread during bur n i ng . T he
thread end does not melt together.
–
Open the head cover.
All functions of the controls are blocked.
–
Loosen the nuts 1 .
–
Set the swing movement of the thread deflector 3 by sliding th e
cylinder s usp en s i on up or d ow n.
–
Tighten the nuts 1.
2
3
1
34
Page 35
Height of the thread deflector
In the thread l ev e r hi g h p os i t i on of th e u ni t th e thread deflector 3
should move f ree l y pa s t u nd er t he ne ed l e.
–
Place materi a l 4 o f t he maximum allowable thickn ess ( t = 16 mm )
or a spacer under the clamps.
–
Lower the clamps.
–
Turn the main sw itch off.
Caution Risk of Injury !
Turn the main switch off.
Check the height of the thread deflector 3 only with the main switch
turned off.
–
Swing the thread deflector 3 manually past under the needle.
The thread deflector 3 should not thereby strike against the needle.
To correct:
–
Loosen clamping screw 2.
–
Adjust the h ei g ht of th e t hr e ad de fl e c to r 3.
–
Tighten clamping screw 2.
43
35
Page 36
11. 2 Upper Burning Device
The correct sideways positioning of the burner to the thread is
automatical l y ma de through the attac h me nt of the burning devi c e.
11.2.1 Position of the Fully Extended Burner
With a correct setting the fo l l ow i ng po s i ti o ns m ust be present:
–
The fully extended burner must have a clearance of approx. 1 mm
to the clampe d m at er i a l .
–
The fully extended burner must touch on the thread positioned by
the thread def l ec t or w i th a s li g ht pr e s s ure .
Both requirements are met when the clearance between the upper
edge of the cylinder suspension and the lower edge of the
mounting bracket is 120 mm.
–
Open the head cover.
All functions of the controls are blocked.
–
Loosen the lock nut 2 on the piston rod 1.
–
Set the cleara nc e be tween the upper ed ge of the cylinder
suspension a nd the lower edge of th e m ou nt i ng br a c ket by turning
the piston r od 1.
–
Tighten the lock nut 2.
120 mm
1
2
36
Page 37
11.2.2 Setting the Height Stop of the Burner
–
Place materi a l 1 o f t he maximum allowable thickn ess ( t = 16 mm )
or a spacer under the clamps.
–
Lower the clamps.
–
Turn the main sw itch off.
Caution Risk of Injury !
Turn the main switch off.
Set the height stop of the burner only with the main switch turned off.
–
Remove the f ing er g ua r d a ft er loosening the mo un ti n g s c re ws .
The clamping screws 3 are readily accessable.
–
Loose the clamping screws 3 slightly.
–
Pull the height stop 2 downwa rd until it touches the lowered
clamps.
–
Tighten the clamping screws 3.
–
Reattach the finger guard again.
Caution Risk of Injury !
After complet ing th e s e tt i ng wo rk i t is e s sen ti a l th at th e f ing er g ua rd b e
attached again.
12 3
37
Page 38
11.2.3 Angle Position of the Burner
The burner 4 mus t be at an an gl e of approx. 90° to the thread
positioned b y the thread defle c to r 3.
Caution Risk of Injury !
Turn the main switch off.
Set the angle p os i t i on of th e b ur n er only with the m ai n s wi t c h t urn ed
off.
–
Remove the finger guard 2 after loosening the mounting screws.
The clamping s c rews 1 are readil y acc e s s ab le.
–
Loosen the clamping screws 1 slightly.
–
Set the correc t an gl e po s i tion by swingin g t he bu r ne r.
–
Tighten clamping s cr ew s 1.
–
Attach the fi ng er g ua rd 2 again.
Caution Risk of Injury !
After complet ing th e s e tt i ng wo rk i t is e s sen ti a l th at th e f ing er g ua rd b e
attached again.
12
3
4
90°
38
Page 39
11 .3 Lower Burning Device
11.3.1 Prerequi site for the Setting
The following prerequisite applies for the setting of the lower burning
device:
–
The surface 2 on th e s h ut tl e r un be ari n g 1 mu s t l i e pa r all e l to th e
needle plate.
11.3.2 Initial Position
The burner is in its initial position when the piston rod 4 of the cylinder
3 is fully retracted.
In this position the thread puller is outside the area of the needle hole.
1
2
3
4
39
Page 40
11.3.3 Clearance between the Thread Puller and Burner
The clearance between the thread puller 2 and the burner 1 must
be approx. 6 mm in the forward area.
Caution Risk of Injury !
Turn the main switch off.
Set the clearance between the thread puller 2 and burner 1 only with
the main swit c h t ur n ed off.
–
Tilt the machine head to the side.
–
Loosen screws 3 slightly.
–
Set the correc t c l ea ran c e b y rel o c at i ng th e t hr e ad pu l l er 2 .
–
Tighten screws 3.
11.3.4 Position of the Swung-forward Burner
The left side of the burner 1 must end in line with the outer edge
of the needle hole bushing 6.
Caution Risk of Injury !
Turn the main switch off.
Set the positi on of th e b urn er 1 on l y wi t h t he ma i n sw i tc h tu rne d o ff.
–
Loosen the lock nut 5.
–
Set the position of the burner by turning the stopper screw 4.
–
Tighten the lock nut 5.
1
2
3
4 5
40
Page 41
11.3.5 Height of the Burner
The swung-forward burner 1 must touch the needle hole
bushing 6 with light pressure.
In the initial position the burner 1 may touch no other part.
Caution Risk of Injury !
Turn the main switch off.
Set the height of th e b urn er 1 on l y wi t h t he ma in s w i tch tu r ne d o ff.
To correct:
–
Bend the burn er 1 appropriatel y.
11.3.6 Height of the Thread Puller
The clearance between the thread puller 2 and the thread guide
plate 7 must as sm al l a s p os si b le .
The inclined position of the thread resulting therefrom aids in the
burning proce s s.
The underthrea d s h ou l d, ho we v er, not be cl am pe d i n be tween the
thread puller 2 and the thread guide plate 7.
Caution Risk of Injury !
Turn the main switch off.
Set the height of th e t hre ad pu l l er 2 on l y wi t h t he ma i n switch turned
off.
To correct:
–
Bend the thread pu l l er 2 do wn wa r d app r op ri at el y.
6
1
2
7
41
Page 42
12. V- belt Tension
The notched V-belt must be under sufficient tension for the unit to run
softly into th e e nd po si ti o n.
Tension the notched V-belt so that it can be pushed in at the
center approx. 10 mm by finger pressure.
Caution Risk of Injury !
Turn the main switch off.
Set the V-belt tension only with the main switch turned off.
To correct:
–
Loosen nut 1.
–
Swing the sew i ng dr i ve 2 until the co rr ec t V-belt tens i o n is
achieved.
–
Tighten nut 1.
1
2
42
Page 43
13. Setting the bobbin winder
The setting of spring 1 of the thread layer must be such that the
thread layer switches off when the bobbin is full.
Caution Risk of Injury !
Turn the main switch off.
Set the bobbin winder only with the main switch turned off.
To correct:
–
Loosen lock nut 2.
–
Adjust the s p ri ng of th e thread layer 1 b y tu rni n g s c re w 3 .
–
Tighten lock nut 2.
1
2
3
43
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