Duerkopp Adler 975-1-5 Service Instructions Manual

Contents Page:

Part 3: Service Instructions Cl. 975 - 1 - 5

1. General ................................................. 3

2. Machine Head ............................................. 4

2.1 LoopingStroke............................................. 4

2.2 NeedleBarHeightandClearanceoftheHookPointtotheNeedle................ 5

2.3 NeedlePlate .............................................. 6

2.3.1 LateralPositionoftheNeedlePlateCarrier............................. 6

2.3.2 UpperandLowerPositionoftheNeedlePlateCarrier....................... 7

2.3.3 TimingoftheSwitchOperation.................................... 8

2.3.4 Speedof“NeedlePlateUpandDown”............................... 9

2.4 BobbinCaseOpener.......................................... 10

2.4.1 HeightoftheFinger .......................................... 10

2.4.2 SizeoftheOpeningGap(PositionoftheFingerRun)andFingerDepth ............ 11

2.4.3 TimingtheOpening .......................................... 12

2.5 PressureFoot ............................................. 13

2.5.1 PressureFootPressure........................................ 13

2.5.2 HeightAdjustmentRange....................................... 14

2.5.3 TimingofthePressureFootMovement ............................... 15

2.6 ThreadControllerSpring ....................................... 16

2.7 ThreadTensionOpening ....................................... 17

2.8 Lubrication ............................................... 18

2.8.1 RegulatingtheLubrication ...................................... 19

2.9 SewingArm............................................... 21

2.9.1 PositionoftheSewingArm ...................................... 21

2.9.2 EndPositionDampeningoftheCylinder............................... 22

2.9.3 TimingoftheOperationoftheSwitches............................... 23

2.10 AdjustmentScrewsfortheTimingBelt................................ 24

3. Thread Trimmer ............................................ 25

3.1 FunctionSequence .......................................... 25

3.2 PositionoftheBasePlateandtheGuideCurve .......................... 26

3.3 ClearancebetweentheDriveSegmentandGuideCurve ..................... 27

3.4 CounterKnifeandThreadPullKnife................................. 28

3.5 CounterKnifePressure ........................................ 29

4. Clamping Table ............................................ 30

4.1 LargeGuideCurve........................................... 30

4.1.1 AttachingtheAluminiumStrips.................................... 31

4.2 ChangingtheStitchLength...................................... 32

Contents Page:

4.3 SmallGuideCurves ......................................... 33

4.3.1 FunctionoftheGuideCurves .................................... 33

4.3.2 PositiontheGuideCurvesontheShaft............................... 34

4.3.3 PositionoftheAluminiumStripsontheGuideCurve ....................... 35

4.4 SwitchingDisks............................................ 36

4.4.1 FunctionoftheSwitchingDisks................................... 36

4.4.2 PositionoftheSwitchingDisksontheShaft............................ 37

4.5 PositionoftheClampingTablees .................................. 38

4.6 FixedClamp.............................................. 39

4.7 SwingClamps............................................. 41

4.7.1 RenewingtheCoatingsontheSwingClamps ........................... 43

4.8 InteriorSlides............................................. 44

4.8.1 SettingtheInteriorSlides ...................................... 45

4.9 SideSlides .............................................. 47

4.10 OuterForwardSlide ......................................... 48

4.11 CenterForwardSlide......................................... 49

4.12 InnerForwardSlide.......................................... 50

4.13 Hold-down............................................... 52

5. Causes of Unequal Edge Intervals ................................ 53

6. Synchronizer ............................................. 55

7. Pneumatics .............................................. 56

8. Maintenance ............................................. 57

1. General

These Service Instructions for the 975 - 1 - 5 describe the settings for
thesewingunit.

ATTENTION

The tasks described in the Service Instructions may only be carried
out by specialists or approp riately trained personnel !

Caution Risk of Injury

During r epair, conver sion and mainte nance work turn the main sw itch
off.

Adjustment work and function testin g with the machine running may
only be conducted with greatest caution under strictest observence of
all safety measures.

3

2. Machine Head

2.1 Looping Stroke

The looping stroke is the path of the needle bar from lower dead center
up to the point where the hook point lies at the center of the needle.

Caution Risk of Injury !

Conduct adjustment work and function testing only with greatest
possible caution.

–

Lower the sewing head.
Set the program switch to 44 andpressthe“STOP ”key.
The sewing head is lowered.

–

Turn the needle bar into the lowest position with the handwheel.

–

Withtheblock2pressthegauge1againsttheneedlebarbushing.

–

Tighten screw 3.

–

Pull ou t the gauge and turn the handwheel in the direction of run
until the block touches the needle bar bushing.
In this position the hook point must be at the center of the needle.

–

Loosen screws 4 and 6.

–

Turnhook5onthedriveshaft.

–

Tighten screws 4 and 6.

Block Order n o. : 981 150002
Gauge Order no. : 981 150003

1

2

3

4

5

6

4

2.2 Needle Bar Height and Clearance of the Hook Point to the Needle

In the looping stroke position the hook point 2 lies at the center of the
furrow.

In the looping stroke position the clearance of the hook point to the
furrow should be 0.1 mm.

Caution Risk of Injury !

Conduct adjustment work and function testing only with greatest
possible caution.

–

Lower the sewing head.
Set t he program s witch to 44 andpressthe“STOP ”key.
Thesewingheadislowered.

Needle bar height

–

Bring the needle bar into the looping stroke position with the
handwheel.

–

Loosen screw 1.

–

Move th e needle bar.
The cen ter of the furrow must lie at the hook point 2.

–

Tighten screw 1.

Clearance to the hook point

–

Loosen screws 3 and 5.

–

Axially slide the hook 4 on the shaft.
The clear ance between the hook point a nd the furr ow is 0.1 mm.
Do not turn the hook.
Do not push the oil whizzer d isk too far to the back.

–

Tighten screws 3 and 5.

1

2

3

4

5

5

2.3 Needle Plate

During t he sewing sequence the needle plate is always in the upper
position.

The ne edle hole mushr oom is bevelled on the inside so t hat the trim, at
the beginning of the sewing procedure, cannot be pushed away and
builds no folds.

The functions “ needle plate up ”and“machine head down ”are
triggered simultaniously. The function “ needle plate down ” occurs
only after the machine head has left its lower position and operated
the valve . With this function sequence, the cut-off end of the needle
thread is pulled out of the area of the ne edle plate bef ore this has a
chance to clamp the thread.

2.3.1 Lateral Position of the Needle Plate Carrier

The ne edle should ent er the needle hole of the raised needle plate
centered.

Caution Risk of Injury !

Turnthemainswitchoff.
Adjust the position only with the sewing unit turned off.

–

Remove the oilpan.

–

Loosen the set collars 2 and 3 on the left side the shaft .

–

Align the needle plate carrier 1 sideways.
The n eedle hole must lie centered under the needle.

–

Place t he set collars 2 and 3 tight and tighten the screws.

–

Attach the oilpan again.

1

2

3

6

2.3.2 Upper and Lower Position of the Needle Plate Carrier

In the upper position there is a clearance of 27.7 mm between the
upper edge the needle plate 1 and t he lower edge of the pin 2.

In the lower position there is a clearance of 20.3 mm between the
upper edge the needle plate 1 and t he lower edge of the pin 2.

Caution Risk of Injury !

Conduct adjustment work and function testing only with greatest
possible caution.

Upper Position

–

Lower the sewing head.
Set t he program s witch to 44 andpressthe“STOP ”key.
Thesewingheadislowered.

–

Loosen the lock nut an d adjust the stop screw 3.
The clearance between the upper edge of the needle plate 1 and
the lower edge of the pin 2 is 27.7 mm.

–

Tighten the lock nut.

Lower Posi tion

–

Remove the oilpan.

–

Set the program switch to 44 andpressthe“STOP ” key. The
sewing head is lowered an d the needle plate and pressure foot are
raised.

–

Press the “ START ”key.
With the “ Σ ” key the sew ing head can now be raised and lowered

again a s often as desired.

–

Loosen the lock nut an d adjust the stop screw 4.
The clearance between the upper edge of the needle plate 1 and
the lower edge of the pin 2 is 20.3 mm.
The ho ok must run through freely und er the needle plate.

–

Tighten the lock nut.

–

Attach the oilpan again.

1

2

34

7

2.3.3 Timing of the Switch Operation

In the upper position of the needle plate switch 2 ( b20 ) should be
triggeredbythestrip3.

In the lower position of the nee dle plate switch 1 ( b19 ) should be
triggeredbythestrip3.

Caution Risk of Injury !

Conduct adjustment work and function testing only with greatest
possible caution.

Upper position switch

–

Set the program switch to 63 and press the “ STOP ”key.

–

Set the program switch to 20.

–

Bring the needle plate m anually into the lower position.
The display must show “- b20 ”.
If not, the switch position m ust be corrected.

Lower position switch

–

Set the program switch to 63 and press the “ STOP ”key.

–

Set the program switch to 19.

–

Bring the needle plate manually into the upper position.
The Display must show “-b19”.
If not, the switch position m ust be corrected.

1

2

3

1

2

8

2.3.4 Speed of “ Needle Plate Up and Down ”

The needle plate is brought into the upper or lower position by cylinder 3.

Caution Risk of Injury !

Conduct adjustment work and function testing only with greatest
possible caution.

“ Needle plate up ” speed

–

Set the throttle 1.

–

Conduct a function test.
Set t he program s witch to 44 andpressthe“STOP ”key.The

sewing head is lowered and the needle plate and pressure foot
raised.
Press the “ START ”key.

With the “ Σ ” key the sewing head, needle plate and pressure foot
can now be raised and lowered again as often as desired.
The needle plate should move up quickly, but not with a jerk.
If not, then the throttle 1 must be set again.

“ Needle plate down ” speed

–

Set the throttle 2.

–

Conduct a function test.
Set t he program s witch to 44 andpressthe“STOP ”key.The

sewing head, the needle plate and the presser foot will be lowered.
Press the “ START ”key.

With the “ Σ ” key the sewing head, needle plate and presser foot
can now be raised and lowered again as often as desired.
The needle plate should move down quickly, but not with a jerk.
If not, then the throttle 2 must be set again.

1

2

3

9

2.4 Bobbin Case Opener

The thread lever must pull the thread through between the middle
piece 5 and its holder 4.
In order for this procedure to occur unimpaired, the middle piece must
at this moment be opened by the bobbin case opener.
This allows the desired seam formation to be achieved with the lowest
possible thread tension.

False setting can have the following effects:
–

Thread breakage.

–

Eyes on the reverse of the cloth.

–

Loud noises.

2.4.1 Height of the Finger

The finger 1 should be at the same height as the nose of the middle
piece.

Caution Risk of Injury !

Conduct adjustment work and function testing only with greatest
possible caution.

–

Lower the sewing head.
Set the program switch to 44 andpressthe“STOP ”key.
The sewing head is lowered and the needle plate and pressure
foot raised.

–

Loosen the screw 2.

–

Turn the eccentric 3.

–

Tighten screw 2.

1

2

3

45

10

2.4.2 Size of the Opening Gap ( Posi tion of the Finger Run ) and Finger Depth

Thegapxbetweentheopenedmiddlepiece4andits
holder 3 should be appropriate for the thickness the t hread to be sewn.

The fing er should ha ve a clearance of approx. 0.6 mm to the middle
piece.
At this clearance the thread can slip through unhindered between the
finger and middle piece.

Caution Risk of Injury !

Conduct adjustment work and function testing only with greatest
possible caution.

–

Lower the sewing head.
Set t he program s witch to 44 andpressthe“STOP ”key.
The sew ing head is lowered and the needle plate and pressure
foot raised.

Opening gap

–

Loosen screw 2.

–

Alter the position of the finger 1.

–

Tighten screw 2.

Depth

–

Loosen screw 2.

–

Alter the depth of the finger 1.
The gap between the middle piece and the finger must be 0.6 mm.

–

Tighten screw 2.

1

2

34

X

11

2.4.3 Timing the Opening

The middle piece should be opened at the moment the thread slips
through between the middle piece 2 and its holder 1.

Caution Risk of Injury !

Conduct adjustment work and function testing only with greatest
possible caution.

–

Lower the sewing head.
Set the program switch to 44 andpressthe“STOP ” key.
The sewing head is lowered and the needle plate and pressure
foot raised.

–

Loosen screw 3.

–

With the handwheel bring the needle bar 1 mm behind the upper
dead center (seen in the direction of run).

–

Turn eccentric 4 until the finger is at the forward reversing point.
The middle piece 2 must be completely open.

–

Tighten screw 3.

3

4

12

12

2.5 Pressure Foot

In the cross seam the opened beard clamp can no longer clamp the
material. In order to avoid missing stitches the pressure foot is lowered.

The low ering of the pressure foot occur s at the same time as the
opening of the beard clamp.

2.5.1 Pressure Foot Pressure

The pressure foot should follow the triggering mechanism during the
downward movement.

Too low pressure foot pressure can lead to missing stitches.

Caution Risk of Injury !

Turnthemainswitchoff.
Adjust pre ssure foot pressu re only with the sewing unit turned o ff.

–

Set t he pressure fo ot pressure with screw 1.

1

13

2.5.2 Height Adjustment Range

When the lowest stroke pos ition is in effect the pressure foot at the
lower dead center should have a clearance of 2.5 mm to the needle
hole mush room.

Caution Risk of Injury !

Conduct adjustment work and function testing only with greatest
possible caution.

–

Lower the sewing head.
Set the program switch to 44 andpressthe“STOP ”key.
The sewing head is lowered and the needle plate and pressure
foot raised.

–

Loosen the wing nut 4 and arrest the lever 5 in the low est position.

–

Loosen nut 1.

–

Press bolt 2 down to the end of the slot.

–

Tighten nut 1.

–

Pull leve r 3 forward until the piston rod of the cylinder is run out
completely.

–

With t he handwheel bring the pressure foot into the low position.

–

Screw off the head c over 8.

–

Loosen screw 6.

–

Set th e presser bar 7.
The clearance between the pressure foot and the needle hole
mushroom must be 2.5 mm.

–

Tighten screw 6.

–

Screw the head cover 8 on again.

ATTENTION !

After setting the height adjustment range set the pressure foot stroke
position ( see Operating Instructions ).

1
2
3
4

5
6
7
8

14

2.5.3 Timing of the Pressure Foot Movement

The pressure foot should reach lower dead center together with the
needle bar. The upward movement of the pressure foot begins only
after the looping stroke.

Caution Risk of Injury !

Conduct adjustment work and function testing only with greatest
possible caution.

–

Lower the sewing head.
Set t he program s witch to 44 andpressthe“STOP ”key.
The sew ing head is lowered and the needle plate and pressure
foot raised.

–

Remove plug 1.

–

Loosen both screws on the stroke eccentric.

–

Turn the stroke eccentric 2 on the shaft.
The axial position may not be changed.

–

Tighten both screws on the stroke eccentric again.

–

Insert plug 1 again.

1

2

15

2.6 Thread Controller Spring

The threa d controller spring 2 should have just reac hed its lowest
position wh en the needle has entered the cloth up to the eye.

Caution Risk of Injury !

Turnthemainswitchoff.
Set the thread controller spring only with the sewing u nit turned off.

Run

–

Turn the handwheel until the needle has entered the c loth up to the
eye.

–

Loosen screw 5.

–

With the bolt 4 turn the whole thread tension unit 3.
The thr ead controller spring 2 must just have reached its lowest
position.

–

Tighten screw 5 again.

Tension

–

Loosen screw 5.

–

Pull the thread tension unit 3 out.

–

Loosen screw 1.

–

Adjust bolt 4.

–

Tighten screw 1 again.

–

Reinsert the thread tension unit 3 again.

–

Tighten screw 5 again.

1
2

3

4

5

16

2.7 Thread Tension Opening

The thread tension opening occurs during the trimming sequence via
the m agnet in the head cover or manually by pressing the pin 1.

Caution Risk of Injury !

Turnthemainswitchoff.
Set the thread tension opening only with the sewing unit turned off.
Conduct a function test only with the greatest possible caution.

–

Loosen screw 3.

–

Displace the thread tension unit 2 axially.
With pin 1 pressed in the thread must be able to be manually
pulled unhindered through the opened tension.

–

Tighten screw 3 again.

Function test

–

Turn the main switch on.

–

Set the program switch to 64 andpressthe“STOP ”key.
Set t he program s witch to 9.

–

Press the “ O ”key.
The tread tension unit is opened by the magnet.
The thr ead must be able to be manually pulled u nhindered through
the opened tension.

1

2

3

17

2.8 Lubrication

Oil feed to the sewing head

The hook drive shaft 8 feeds the oil from the pan through the tube 4 to
the sew ing head via spiral grooves . The window 2 over the tube
makes possible a check of the oil feed. A part of the oil fed to the
sewing head is used for the lubrication of the mechanical parts in the
sewing head. The other part of the oil runs through the tube 1 to the
filler neck. From here the arm shaft bearings and the foot stroke
mechanism are lubricated via wicks.

Oil return from the sewing head

The oil spun off in the sewing head collects in the lower part of the
sewing head where there is also the suction tube 3 with the metal filter.
Via this tube the pump 5 on the hook drive shaft sucks the oil back
again.

Oil feed to the hook

Along with the oil from the sewing head the pump 5 also sucks oil out
of the oilpan. This oil reaches the pump via a tube. A rubber gasket
prevents the tube end from lying directly on the bottom of the oilpan.
This avoids dirt particles from being sucked in which could block the
channel t o the hook.
The pu mp transports the sucked-in oil t hrough a pre ssure tube in a
channel. From here the oil reaches the hook via the oil whizzer disk.
The oil not required for lubrication of the hook flows off beforehand
through a hole in the pressure tube.

6 = Oil drain screw
7 = Viewing glass

3

4

5678

12

18

2.8.1Regulating the Lubrication

Caution Risk of Injury !

Regulating the lubrication and checking are only to be conducted with
greatest possible caution.

Checking the oil level and the oil feed

–

Turn the sewing u nit off and wait until the oil has collected.
The view ing glass 3 must be half filled.
If not, then fill ESSO SP-NK 10 oil u p to the top edge of the
viewing glass.

–

Turnthesewinguniton.
At the window 1 check if enough oil is being fed to the sewing head.

Regulating the sewing head lubrication

The set oil quantity sho uld be considerab ly greater than the actually
required oil quantity. The pump sucks the oil from the lowest point of
the he ad back into the pan again.

–

Screw the head cover off.

–

Turn screw 2 com pletely in an d then loosen by approx. 1/2 of a
turn.

–

Let the sewing unit r un approx. 2 minutes.

–

Hold a piece of paper between the presser bar a nd the cast wall.

–

Let the sewing unit r un at intervals and check if sufficient oil is
being s pun onto the paper.
If not, then adjust screw 2 accordingly.

Increase the quantity of oil = Turn screw 2 to the left
Decrease the quantity o f oil = Turn screw 2 to the right.

Continued on the next page !

1

2

3

19

Caution Risk of Injury !

Regulating the lubrication and checking are to be conducted only with
the greatest caution.

Regulating the hook lubrication

The hook can only be lubricated if the oil whizzer disk is in the shell
area of the hook. The hook should be safely lubricated with a smallest
possible amount of oil so that a little oil as possible is consumed.

–

Turn screw 1 co mpletely in and then loosen by approx. 1/8 turn.

–

Let t he sewing un it run appr ox. 2 minutes.

–

Hold a piece of paper under the hook.

–

Let t he sewing un it run at intervals and check if sufficient oil is
being spun off onto the paper.
If no t, then adjust screw 1 accordingly.

Increase the quantity of oil = Turn screw 1 to the left
Decrease the quantity o f oil = Turn screw 1 to the right.

1

20

2.9 Sewing Arm

2.9.1 Position of the Sewing Arm

With low ered sewing arm 1 the clearance between the milled bottom of
thesewingarmandthelowerarmsurfaceshouldbe72.5mm.

Caution Risk of Injury !

Conduct adjustment work and function testing only with greatest
possible caution.

Lower position

–

Remove the feed plate 4.

–

Lower the sewing head.
Set t he program s witch to 44 andpressthe“STOP ”key.
The sew ing head is lowered and the needle plate and pressure
foot raised.

–

Loosen screw 2 and turn piston rod 3.
With low ered sewing a rm 1 the clearance between t he milled
bottom of the sewing arm and the lower arm surface should be

72.5 mm.

–

Tighten screw 2.

Upper position

The upper position need not be set.
It results from the piston rod run of the cylinder.

1

2

3

4

21

2.9.2 End P osition Dampening of the Cylinder

The spe ed of the piston rod is reduced approx. 10 mm in front of the
end p osition in order to softly brake the heavy sewing head.

Caution Risk of Injury !

Conduct adjustment work and function testing only with greatest
possible caution.

End position dampening “ raise sewing head ”

–

Set the throttle 2.

–

Conduct a function test.
Set the program switch to 44 andpressthe“STOP ” key. The

sewing head is lowered and the needle plate and pressur e foot
raised.
Press the “ START ”key.

With the “ Σ ”keythesewingheadcannowberaisedandlowered
again as often as desired.
The se wing head should run softly into the end position.
If not, then throttle 2 must be reset.

End position dampening “ lower sewing head ”

–

Adjust throttle 1.

–

Conduct a function test.
Set the program switch to 44 andpressthe“STOP ” key. The

sewing head is lowered and the needle plate and pressur e foot
raised.
Press the “ START ”key.

With the “ Σ ”keythesewingheadcannowberaisedandlowered
again as often as desired.
The se wing head should run softly into the end position.
If not, then throttle 1 must be reset.

1

2

22

2.9.3 Timing of the Operation of the Switches

In the upper position of the sewing arm switch 2 ( b17 ) should be
triggered.

In the lower position of the se wing arm switch 1 ( b18 ) should be
triggered.

Caution Risk of Injury !

Conduct adjustment work and function testing only with greatest
possible caution.

Upper switch position ( b17 )

–

Set the program switch to 63 andpressthe“STOP ”key.

–

Set the program switch to 17 .

–

Bring the sewing head manually into the u pper position.
The display must show “ -b17”.

If not, then the switching point ( switch 1 ) must be adjusted.

–

Adjust bushing 4 ( switching point ).
The bushing 4 should, in this position, have approx. 5 mm
clearance from the plate.

Lower switch position ( b18 )

–

Set the program switch to 63 andpressthe“STOP ”key.

–

Set the program switch to 18 .

–

Bring the sewing head manually into the lo wer position.
The display must show “ -b18”.

If not, then the switching point ( switch 2 ) must be adjusted.

–

Adjust bushing 3 ( switching point ).
The roller of switch 2 ( b18 ) should lie at the center of the
cylindrical part of the bushing 3 in this position.

1

2

1

34

23

2.10 Adjustment Screws for the Timing Belt

The tw o contact rollers 1 prevent the timing belt from jumping off the
belt pu lley when the sewing head is raised.

Caution Risk of Injury !

Conduct adjustment work and function testing only with greatest
possible caution.

Switch upper position

–

Set the program switch to 44 and press the “ STOP ”key.
The sewing head is lowered .

–

Loosen screw 2 and set the lever with the contact roller 1. Thereby
lightly press the contact roller 1 onto the belt.

–

Tighten screw 2 again.

–

Repeat the procedure with th e 2nd contact roller.
The belt must run easily.

If not, then the two contact rollers mu st be set again.

1

2

24

3. Thread Trimmer

3.1 Function Sequence

When, after the “ seam end ” signal, the 1st position is reached, the
thread t rimmer magnet is switched on and the drive segm ent pressed
against the guide curve. T he thread te nsion is opene d and the sewing
unit ru ns at the cutting rpm of 160 min

-1

.

When the drive segment of the magnet is pulled into the recess of the
guide curve, then the thread pull knife is swung into the needle thread
loop. The needle thread and the underthread f all behind the thread pull
hook o f the knife.

When the drive segment is pressed out of the guide curve recess, then
both threads are pulled to the counter knife and cut shortly before the
thread lever high position.

When the thread lever high position and thereby the 2nd position are
reached the motor stops. The magnet for the thread tension opening is
turned off and the magnet for the thread trimmer is turned off.

General information

–

The n eedle thread length is influenced b y the pre-te nsion.

–

After a missing stitch the needle t hread is not cut.

–

Replace dull knives only as pairs.

–

When checking and correcting the settings proceed in the order
described.

25

3.2 Position of the Base Plate and the Guide Curve

The height of the base plate determines the clearance of the thread
pull knife to the hook.

The po sition of the guide curve determine s the timing of the swinging
in and out of the thread pull knife.

Caution Risk of Injury !

Turnthemainswitchoff.
Set the base plate only with the sewing unit turned off.

Base plate

–

Remove the hook.

–

Loosen screws 3 and 4.

–

Loosen the hex-head bolt 2.

–

Placegauge5ontheshaft.

–

Press the base plate 1 up against the gauge.

–

Tighten screws 3 and 4.

–

Tighten the hex-head bolt 2.

Gauge Order no.: 396 351050

Guide curve

–

Turn the handwheel until the needle 6 lies approx. 2 mm above the
top edge the needle plate 7.

–

Loosen the screw.

–

Turn guide curve 8 .
The dr ive segment should touch the guide curve a pprox. 1 mm
behind the flat part.

–

Align th e guide curve axially.
The guide curve should lie centered to the drive segment.

–

Tighten the screw.

1

2
3

4

5

8

6

7

26

3.3 Clearance between the Drive Segment and the Guide Curve

When the drive segment 4 is swung completely back the re should be a
clearance of 0.2 mm between it and the guide curve 3.

Caution Risk of Injury !

Turnthemainswitchoff.
Set t he clearance on ly with the sewing unit turned off.

–

Loosen screw 2.

–

Turn the magnet anchor 1.
The clear ance between the drive segment 4 and guide cur ve 3
should be 0.2 mm.

–

Tighten screw 2.

Note

–

With too much play the thread pull knife cannot swing far enough
to the back and not capture the threads.

–

At this setting the function of the spring 5 in the drive segment and
the easy movement of the drive segment 4 should be checked at
thesametime.

1

2

45

3

27

3.4 Counter Knife and Thread Pull Knife

The clearance of the counter knife 2 to the needle 1 should be 4 mm.
The position of the thread pull knife 3 to the counter knife determines

the knife overlapping and th e timing of the cutting.

Caution Risk of Injury !

Turnthemainswitchoff.
Set t he thread pu ll knife and counter knife only with the sewing unit
turned off.

Counter knife

–

Loosen screw 4.

–

Set the clearance.
The clearance between needle and counter knife 2 is 4 mm.

–

Tighten screw 4.

Thread pull knife

–

Turn the handwheel until the thread lever is in its highest position.

–

Loosen screws 5 and 6.

–

Set the position of the thread pull knife 3.
Thebladesshouldbeoverlapped0.5mm.
The t ip of the thread pull knife should lie centered to the needle.

–

Tighten screws 5 and 6 again.

12

4

2

35 6

3

28

3.5 Counter Knife Pressure

The knife should securely cut with the least possible amount of
pressure.

Caution Risk of Injury !

Turnthemainswitchoff.
Set the guide plate and counter knife pressure only with the sewing
unit turned off.

Counter knife pressure

–

Loosen screw 1.

–

Swing the carrier 2 with counter knife.

–

Tighten screw 1.

–

Conduct a check.
Place a thread behind the pulling hook of the swung-back thread
pull knife. Swing the thread pull kn ife manually to the counter knife.
If the thread is not cut flawlessly the counter knife pressure must
be re set.

2

1

29

4. Clamping Table

4.1 Large Guide Curve

During the automatic operation the aluminium strips trigger the
functions listed in the table v ia the initiators.

Pos. Function Effect of an incorrect

activation point

1 Starting the sewing cycle - Thread breakage through

after a set time. sewing in place.

- Lo wered sewing head
collides w ith the clamp.

- Maximum sewing length
not possible.

2 Slow sewing - Time loss

- U nequal seam inte rval

3 Opening the beard clamp - Unequal seam interval.

Lower the pressure foot - Se am run not squared off.

- Be ard clamp collides
with the pressure foot.

- “ Tearing ” of the cloth.

- Missing stitches.

4 Stop the sewing cycle - Bartacking too short.

- Ba rtacking too long.

5 Bring the folding device - Insignificant

into the “removal p osition”

6 Stopping the clamping - Insignificant

table in the initial position

1

30

4.1.1 Attaching the Aluminium Strips

The aluminium strips are attached to the side surfaces of the large
guide curve 1.

The position of the aluminium strips is shown for the right clamping
table. For the left clamping table it is a mirror image.

Caution Risk of Injury !

Turnthemainswitchoff.
Attach the strips only with the sewing unit turned off.

–

With the hand crank run the clamping table to the switching points
1, 2, 3, 4 and 6. M ark each of the switching points on the side
surface of the guide cur ve.
Switching p oint 1 is reached when the direction of movement of the
clamping table no longer changes.

Switching p oint 5 results from the length of the strip.

–

Mark the delay distances on the guide curve.
Because of the reaction t imes the signals must be triggere d earlier
accordingly.

Points: 1, 2 ,6 Delay distance approx. 20 mm
Points: 3, 4 Delay distance approx. 10 mm

–

Cut the strip to size.
1 to 2: appropriate to the marking (taking delay distances into account)
3to5: 400mm
4: 70 mm
6: 80 mm

–

Attach the strips.
4 and 6: Top
1 until 2: Center
3 until 5: Bottom

–

Check the switching points in automatic operation.

Caution Risk of Injury !

Conduct a function test with the greatest possible caution.

If necessary correct the position and length of the aluminium strips.

1

31

4.2 Changing the Stitch Length

The tension pulley 2 on the V-belt determines the stitch length.
The belt adjustment gearing on the motor is changed by the tension. A

stitch length of 1.8 mm is set at the factory.

Caution Risk of Injury !

Turnthemainswitchoff.
Change the stitch length only with the sewing unit tur ned off.

–

Loosen lock nut 1.

–

Turn the star knob 3.
Shorter stitches = Tension pulley lower

Longer stitches = Tension pulley higher

–

Tighten the lock nut 1.

ATTENTION !

After a stitch length change the follow ing points must be observed.

–

The performance of the sewing unit has changed.

–

The p osition of the sew-on point has changed.
Set the seam beginning again !

–

If the positions of the sew-on points of the right and left clamping
tables do not agree, then the stitch length has been set differently.

Set t he stitch length again !

2

3

1

32

4.3 Small Guide Curves

4.3.1 Function of the Guide Curves

The 3 guide curves no.s 1 to 3 mechanically trigger the functions listed
in the table via the inner a nd outer cur ve runs 1.

a = Outer guide curve
i = Inner guide curve

Guide Curve Function

No. 1 outer Side slides - Fixed table

forward and back

No. 1 inner Outer forward slide

forward and back

No. 2 outer Center forward slide and

side slides - Swing table

forward and back

No. 3 outer Sleeve table

up an d down

No. 3 inner Swing table

turn forward and back

1

33

4.3.2 Position of the Guide Curves on the Shaft

The guide curve no. 1 should, after a turn of 20°, start with the forw ard
movement of the side slide s of the fixed table.

The drilled orientation hole 1 in the guide curves no. 2 and no. 3 must
be in line with the drilled orientation hole of the guide curve no. 1.

Caution Risk of Injury !

Turnthemainswitchoff.
Set t he guide cur ves only with the sewing unit turned off.

–

Bring the folding device of the clamping tables into the base
position.

–

Screw the setting disk 4 onto the shaft 3.
Align the setting disk so that the 0° position agrees with the edge 2
of the mounting plate for the valves.

–

Set the program switch to 40 and press the “ STOP ”key.
Turn the shaft with the guide curves using the “ REPEAT ”key.
At 20° the forward movement of the side slides of the fixed table
must be gin.
If not, then turn guide curve no. 1 on the shaft.

–

Align the guide curves no.s 2 and 3 so that the drilled orientation
holes are in line.
Check with a 5 mm diameter pin.

1

2

3

4

34

4.3.3 Position of the Aluminium Strips on the Guide Curves

The alumin ium strips 1 on the faces of the 3 g uide curves stop their
turning mo vement according to the function sequence.

Caution Risk of Injury !

Turnthemainswitchoff.
Attach the aluminium strips to the guide curves only with the sewing
unit turned off.

Guide Curve Function

No. 1 A = 0° Initial position of the folding device

No. 2 B = 235° Sewing position of the folding device

No. 3 C = 116° Insert the sleeve

D = 177° Short intermediate stop
E = 261° Remove the cloth

–

Bring the folding device of the clamping table into the base position.

–

Cut the aluminium strips to size.
A=80mm. B,C,D,E=15mm.

–

Screw the setting disk 4 onto the shaft 3.
Align the setting disk so that the 0° position agrees with the edge 2
of the mounting plate for the valves.

–

Set the program switch to 40 andpressthe“STOP ”key.
Turn the shaft with the guide curves into the individual positions
using th e “ REPEAT ”key.

–

Attach the aluminium st rips.

–

Check the switching points in automatic operation.

Caution Risk of Injury !

Conduct a function test with the greatest possible caution.

If necessary correct the position and length of the aluminium strips.

1

2

3

4

35

4.4 Switching Disks

4.4.1 Function of the Switching Disks

The switch ing disks no.s 1 to 10 trigger the function of various
clamping table elements via the pneumatic valves.

Switching Disk Function

No. 1 Forward slide - Inner

forward and back

No. 2 and 3 Fixedclampandsleeveclamp

of the fixed table
close (full pressure)

close (half pressure)

open and pressure-free

No. 4 Swing clamp

open and close

No. 5 Sleeve clamp of the sleeve table

open and close

No. 6 Hold-down

hold op en and closed

No. 7 and 8 Interior slides

forward and back

No. 9 and 10 Trim clamp cylinder for swing clamp

open and close
Cross clamp cylinder for swing clamp

Piston rod run in

Cylinder p ressure-free
Piston rod run out

(with half and with full pressure)

36

4.4.2 Position of the Switching Disks on the Shaft

The switching disks no.s 1 to 10 are arranged as per the setting disk.
The switching disks no.s 3 to 10 are deployed as pairs ( 3 + 4,

5 + 6, 7 + 8, 9 +10 ).

Caution Risk of Injury !

Turnthemainswitchoff.
Set the switching disks only with the sewing unit turned off.

Switching Disk Function

No. 1 165° Valve released - Inner forward slide forward
No. 2 245° Valve released - Fixed clamp pressure-free
No. 4 245° Valveoperated -Swingclampopens
No. 6 30° Valveoperated -Hold-downback
No. 8 163° Valve operated - Interior slides operated
No. 10 232° Valve released - Cross clamp cylinder

has full pressure

–

Bring the folding device of the clamping table into the base position.

–

Screw setting disk 3 onto the shaft 2.
Align the setting disk so that the 0° position agrees with the edge 1
of the mounting plate for the valves.

–

Set the program switch to 40 andpressthe“STOP ”key.
With the “ REPEAT ” key turn the shaft with the switching disks to
the var ious positions and align.

–

Check the switching points in automatic operation.

Caution Risk of Injury !

Conduct a function test with the greatest possible caution.

If necessary correct the position of the switching disks.

1

2

3

37

4.5 Position of the Clamping Tables

The position of the clamping table determines the position of the seam
formation on the trim.

Before the contour determining elements are set, the position of the
clamping table must first be set.

Caution Risk of Injury !

Turnthemainswitchoff.
Set t he position of the clamping table only with the sewing unit turned
off.

–

Loosen screws 2, 3 and 5.

–

Loosen the lock nuts.

–

Set the adjustment screws 1 and 4.
Set t he position of the clamping table so tha t the clearance of the
short side seam is 1 mm.
The sma ller the edge interval is to be, the farther the clamping
table must be distanced from the machine he ad.

–

Tighten the lock nuts.

–

Tighten screws 2, 3 and 5.

The tw o clamping plat es are present at each clamping table !
The settin g is to be made with both clam ping plates !

–

Conduct a function test with low cutting rpm.
Set the program switch to 41 andpressthe“STOP ”key.

Caution Risk of Injury !

Conduct a function test with the greatest possible caution.

The needle hole mushroom should not touch the fixed clamp !
Theneedleshouldnottouchthefixedclamp!

If necessary correct the position of the clamping table.

1

2

3
4

5

38

4.6 Fixed Clamp

During folding the fixed clamp 1 (clamping table left) is pressed
against the hold-down and then against the o uter forward slide with
half pr essure.

When sewing the fixed clamp is pressed against the swing clamp at
full pressure.

When sew ing the cross seam the forward part of the fixed clamp is
swung to the side by the needle hole mushroom. A spring swings the
forward part of the fixed clamp back into the initial position again.

Caution Risk of Injury !

Turnthemainswitchoff.
Set the fixed clamp only with the sewing unit turned off.
Conduct a function test with the greatest possible caution.

Sideways clearance to the rotation axis

The clearance to the rotation axis is 0.5 mm.
It is set at the factory with a gauge and may not be altered.

Height of the fixed clamp

–

Remove the swing clamp 2 (clamping table left).

–

Loosen the lock nut and turn the adjustment screw 3.
The fixed clamp should be 3 mm higher in the forward area than in
the rear area.

–

Reinstall the swing clamp again.

–

Set t he adjustment screw.
During sewing the fixed clamp should have a clearance of 0.5 mm
to the needle plate.

–

Set the program switch to 41 andpressthe“STOP ”key.
Check t he clearance in the (key) interval operation and correct if
necessary.

–

Tighten the lock nut.

Sideways clearance to the needle hole mushroom

The clear ance results fr om the po sition of the clamping table.
If the needle hole mushroom still presses the fixed clamp to the side,

then the position of the side fram e must be checked and possibly
corrected.

3

1

2

39

Speed of opening and closing

–

Set the program switch to 41 and press the “ STOP ”key.
With the “ REPEAT ” key run th rough the f unction sequence in
interval operation.

–

Observe the movement of the fixed clamp 8 when opening and
closing.
The fixed clamp should move quickly and uniformly.
If not, then the throttles 1 and 2 are to be set appropriately.

Renewing the coatings

The rubber clamps the cloth in the area of the forward slides.
–

Pull off damaged rubber.

–

Clean t he adhesive surfac es.

–

Cut the rubbers 6 and 7 to size and affix.

The Delrin 5 should support the cloth as close as possible to the
needle.

Because of its rough surface the chrome foil 4 on the Delrin 5 should
prevent the cloth from being pulled out of the clamp during sewing.

–

Pull off damaged Delrin 5 with the chrome foil 4.

–

Cut strips from the chrome foil and Delrin.
In th e same width s as befor e.

–

Clean t he adhesive surfac es.

–

Affix the Delrin 5 to the fixed clamp.
The D elrin should e nd in line with the inner side of the fixed clamp.

–

Cut 2 mm wide antislip foil 3 and affix to the chrome foil.
The a ntislip foil should end in line with the outer side of the fixed
clamp.

–

Affix the chrome foil 4 with the rough side up onto the Delrin.

–

Check the clearance of the Delrin to the needle.
Set the program switch to 41 andpressthe“STOP ”key.
With the “ REPEAT ” key run th rough the f unction sequence in
interval operation.

–

If necessary correct the clearance by filing the Delrin.

1

2

34567

8

9

40

4.7 Swing Clamp

During sewing the fixed clamp 1 (clamping table left) is pressed
against the swing clamp 2.

The beard clamp on the swing clamp is opened by the guide curve so
that th e machine head can press the beard clamp to the side when
sewing the cross seam.

Caution Risk of Injury !

Turnthemainswitchoff.
Set the fixed clamp only with the sewing unit turned off.
Conduct a function test with the greatest possible caution.

Sideways clearance to the fixed clamp

The clearance to the fixed clamp is 1 mm.
The cleara nce is set in the base position of the folding device.

–

Loosen the screws 4.

–

Turn the eccentric bushings 2 (one each right and left).
The eccentr ic bushings must be set tight.

–

Tighten the screws 4.

Height of the closed swing clamp

The swin g clamp should press the fixed clamp down ward.
In all seam segments the clearance to the needle plate should be

0.5 m m.
–

Loosen lock nut 5.

–

Turn the piston rod extension 6.

–

Tighten lock nut 5.

–

Check the clearance to the needle plate.
Set t he program s witch to 41 andpressthe“STOP ”key.
With the “ REPEAT ” key run through the function sequence in
interval operation.

If necessary correct the clearance.

3

4

1

2

56

41

Cross clamp cylinder

Just before the folding device reaches the sewing position the cross
clamp cylinder 1 turns the swing cla mp against th e fixed clamp at f ull
pressure. This sufficiently clamps th e cloth in the area of the
lengthwise seam.

–

Loosen lock nut 2.

–

Turn the extension 3.
The pressure against the fixed clamp must be sufficiently strong in
theareaofthelengthwiseseam.

–

Tighten lock nut 2.

Trim clamp cylinder

When the folding device has reached the sewing position the trim
clamp cylinder 4 presses the swing clamp in the rear area downward
against the fixed clamp.

–

Loosen screws 6

–

Alter the position of t he cylinder holder 5 appropriately.

–

Tighten screws 6 again.

Speed when opening and closing

–

Set the program switch to 41 and press the “ STOP ”key.
With the “ REPEAT ” key run th rough the f unction sequence in
interval operation.

–

Observe the movement of the swing clamp when opening and
closing.
The sw ing clamp should move quickly and uniformly. If not, set the
throttles 7 and 8 accordingly.

1

2

3
4
5
6

78

42

4.7.1 Renewing the Coatings on the Swing Clamp

Swing clamp

–

Remove damaged sponge rubber 4 and antislip foil 3 from the
spring plate 5 of the swing clamp 6.

–

Cut sponge rubber to size in 9 mm width and affix to the spring
plate 5 .

–

Cut antislip foil to size in 2.5 mm width and affix to the spo nge
rubber.
The antislip foil should end in line with the outer side of the swing
clamp.

–

Remove the antislip foil 1 and D elrin 2 from the s wing clamp 6.

–

Cut the Delrin 2 to size as before and affix to the swing clamp 6.

–

Cut the antislip foil 1 to size as before and affix to the Delrin.

Beard clamp

–

Remove damaged antislip foil 7 from the beard clamp 8.

–

Cut antislip foil 7 to size as before and affix to the beard clamp.

7

8

1
2
3
4

5

6

43

4.8 Interior Slides

The inte rior slides 1 and 2 determine the clearance betwee n the seam
and trim edge in the following seam segments.

Seam Segment Element
Trim Edge

a 2 Interior slides-Swing table
b 2 Interior slides-Swing table
c 3 Inner forward slide
d - Position of the clamping table
e 1 Interior slides-Fixed table
f 1 Interior slides-Fixed table

In order that the interior slides, during their movement into the initial
position, do not pull the folded trim with them, the inner forward slide 3
in this phase must still be in the extended position. The inner forward
slide is thus brought into the initial position 2° later.

The clear ance between seam and trim ed ge is:
aandb = 1mm
f=1.5mm

ATTENTION !

Scratches can occur on the interior slides if the folding device is
activated w ithout cloth.

a

f

1

2

e

b

c

3

ab c d e f

44

4.8.1 Setting the Interior Sl ides

Prerequisite for the setting of the interior slides is the correct
positioning of the clamping table (short side seam d see Page 44).

Caution Risk of Injury !

Turnthemainswitchoff.
Set t he interior slides only with the sewing unit turned off.

Position of the interior slide-Swing table

The clearance of the trim edge a to the long side seam is 1mm.

The clearance of the trim edge b to the pointed seam is 1mm.

–

Loosen nut 2.
Align the interior slide parallel to th e swing clamp.
Tighten nut 2 again.

–

Loosen screws 3.
Set the interior slide so that this extends sideways 1.5 mm relative
to the swing clamp.
Tighten screws 3 again.

–

Loosen screws 1.
Set the interior slide so that this extends forward 1.5 mm relative to
the swing clamp.
Tighten screws 1 again.

ATTENTION !

If the interior slide was changed in the sideways direction,
then the position of the side slide of the swing table is to be checked
and possibly to be corrected.

ab

1

2

3

45

Position of the interior slide-Fixed table

The clear ance between trim edge f at the lower edge and the long side
seam is 1.5 mm.

–

Loosen nut 2.
Align t he interior slide parallel to the fixed clamp.
Tightennut2again.

–

Loosen screws 3.
Set the interior slide so that this extends 2 mm sideways relative to
the fixed clamp.
Tighten screws 3 again.

–

Loosen screws 1.
Set t he interior slide so that forward this is set back 1.5 mm
relative to the rubber of the fixed clamp.
Tighten screws 1 again.

ATTENTION !

If the interior slide was changed in the sideways direction,
then the position of the side slide of the fixed table is to be checked
and possibly to be corrected.

The inte rior slides must be run back in t he sewing po sition and in the
removal positio n.

–

Bring the folding device into sewing position.

–

Loosen lock nut 4.
Turn the extension 5.
The run-back interior slide of the fixed table should have a
clearance of 2 mm to the fixed clamp in the sideways direction.
Tighten lock nut 4 again.

The extend ed piston rod of the interior slide cylinder is fixed laterally
by a plastic guide. The side slides should not push away the in terior
slides during the folding sequence.

–

Loosen screws 7.
Set the position of the carrier 6 with the plastic guide.
The piston rod must run into the slot of the plastic guide without
deflection.
The stroke of the piston rod may not be limited by the plastic guide.
Tighten screws 7 again.

f

4567

1
2

3

46

4.9 Side Slides

The side slides fold the trim around the interior slides.
1 = Side slide-Swing table
2 = Side slide-Fixed table
In the sleeve feed position of th e folding device the interior slide

should hang down. It is therefore held by 2 pins of the swung-forward
side slide.

The hold-down is only then swung back when the side slide is
somewhat above the interior slides.

During of the folding sequence the outer forward slide is swung under
the side slide. The strip below the side slide may not extend into the
slewing area of the outer forward slide. This leads to the trim at this
position not being folded around the side slides with sharp edges.
Slightly variing edge intervals on the side seam cannot be avoided.

Caution Risk of Injury !

Turnthemainswitchoff.
Set t he side slides only with the sewing unit turned off.
Conduct a function test with the greatest possible caution.

–

Loosen screws 3.

–

Align t he side slides 2.
The swung-completely-forward side slides should have a
clearance in agreement with the median material thickness.
The smaller the gap to the side slides the sharper is the folding.
The side slide should not collide with the retracted inner forward
slide during its forward movement.

–

Tighten screws 3.

–

Set the program switch to 41 andpressthe“STOP ”key.
With the “ REPEAT ” key run through the function sequence in
interval operation.

3

2

2

1

47

4.10 Outer Forward Slide

During t he folding sequence the fixed clamp presses t he interior slide
first aga inst the hold- down and t hen against the swung-in outer
forward slide 1 at half pressure.

Caution Risk of Injury !

Turnthemainswitchoff.
Set t he outer forw ard slide on ly with the sewing unit turned off.
Conduct a function test with the greatest possible caution.

Clearance to the interior slide

–

Loosen lock nut 3.

–

Set the tie rod 2

The out er forward slide should, in its initial position, have a

clearance of 1 to 2 mm to the interior slide.

–

Tighten lock nut 3.

Sideways position

–

Loosen screw.

–

Align the position of the outer forward slide on the carrier.

–

Tighten the screws.

Conduct a function test

–

Set the program switch to 41 and press the “ STOP ”key.
With the “ REPEAT ” key run th rough the f unction sequence in
interval operation.

1

2

3

48

4.11 Center Forward Slide

The center forward slide 1 folds the trim around the interior slide and
the inn er forward slide above it.

The trim fold created during folding should be in the recess in the
center forward slide. This is necessary for the folded trim to be held
while the inner forward slide runs b ack into the initial position.

Caution Risk of Injury !

Turnthemainswitchoff.
Set c enter forward slide only with the sewing unit turn ed off.
Conduct a function test with the greatest possible caution.

Setting the position

–

Loosen screws 2.

–

Align the center forward slide.

–

Tighten screws 2 again.

Conduct a function test

–

Set the program switch to 41 andpressthe“STOP ”key.
With the “ REPEAT ” key run through the function sequence in
interval operation.

1

2

49

4.12 Inner Forward Slide

The inner forward slide 1 folds the trim around the interior slide.
Then the center forward slide folds the trim around the inner forward
slide.

The inner forward slide holds the folded trim tight when the interior
slides are pulled back. It is therefor e pulled back into the initial
position 2° later.

Caution Risk of Injury !

Turnthemainswitchoff.
Set t he inner forw ard slide only with the sewing unit turned off.
Conduct a function test with the greatest possible caution.

Setting the position of the edge

–

Loosen screws 2 and 3.

–

Align the position of the inner forward slide with the carrier 8.
The t rim edge sho uld have a clearance of 1 mm to the pointed
seam.

–

Tighten screws 2 and 3 again.

Setting the position of the run-forward forward slide

–

Loosen screw 4.

–

Set eccentric 5.
The front edge of the inner forward slide should lie at the same
height as the beard clam p.

–

Tighten screw 4 again.

Setting the position of the run-back forward slide

–

Loosen screw 6.

–

Set eccentric 7.
The in ner forward s lide should ha ve a clearance of 5 to 6 mm to
the interior slides.

–

Tighten screw 6 again.

Continued on the next page !

1

2
3

4
5
6
7
8

50

Setting the height

During the folding sequence the swing clamp presses the in terior slide
upward against the retracted inner forward slide at half pressure. The
height of the inner forw ard slide also determines the heigh t of the
swing cla mp and of the interior slide.

–

Turn the setting wheel 2 into position 1.

–

Bend the inner forward slide.

Speed of the forward slide forward and back

–

Set the program switch to 41 andpressthe“STOP ”key.
With the “ REPEAT ” key run through the function sequence in
interval operation.

–

Observe the movement of the inner forward slide.
The slide should move quickly but not jerk.

–

Set t he movement with the throttle.

1

2

3

51

4.13 Hold-down

The hold-down 1 is manually swung upward and presses the interior
slides dow n against t he clamps.

At the end of the folding sequ ence the hold-down is swung into the
base position by a pneumatic cylinder.

Caution Risk of Injury !

Turnthemainswitchoff.
Set t he hold-down only with the sew ing unit turned off.
Conduct a function test with the greatest possible caution.

Setting the position

–

Set the dial for setting the material thickness to 1.

–

Loosen screws 3.

–

Set the position of the hold-down by relocating the stop 4.
There should be a cleara nce of 2 to 3 mm between t he casing of
the hold-down and the side slides .

–

Tighten screws 3 again.

Setting the speed

–

Set the program switch to 41 and press the “ STOP ”key.
With the “ REPEAT ” key run th rough the f unction sequence in
interval operation.

–

Observe the movement of the hold-down.
The hold-down should move quickly but not with a jerk.

–

Set the movement with the throttle 2.

Setting the limit switch

–

Loosen the screws.

–

Relocate switches 5 and 6.
The sw itches 5 and 6 ( b23 and b 24 or b27 and b28 ) must be
triggered in both end positions of the hold-down.

–

Tighten the screws again

1

2

3

4
5
6

52

5. Causes of Unequal Edge Intervals

Listed in the table are the contour-determining elements.

Seam Segment Trim Side Element

Trim Edge

a upper Interior slide-Swing table
b upper Interior slide-Swing table
c upper Inner forward slide

d upper Position of the clamping table
e lower Interior s lide-Fixed table
f lower Interior s lide-Fixed table

The possible causes for unequal edge intervals are listed in the
following table.

Possible Causes of Unequal Edge Intervals
Possible Cause Effect on Edge

ab c d e f

Folding Device

Position of the interior slides • • - - • •
Position of the inner forward slide - • • • - ­Position of the clamping table - - - • - ­Interior slides scratched • • • - • •

Position of the side slides • - - - - •
Position of the hold-down • • • - • •
Inner fo rward slide run too far in - - - • - ­Center forward slide in the wrong position - - • • - -

Dial for material thickness set incorrectly • • • - • •
Position of the guide curves and switching disks • • • - • •

Continued on the next page !

ab c d e f

53

Possible Cause Effect on Edge

abcdef

Fixed Clamp / S wing Clamp

Delrin and rubber damaged • • • - - •
Delrin deflects the needle • • • • - •
Trim clamp cylinder in the wrong position • - - - - ­Cross clamp cylinder in the wrong position • - - - - -

Machine Head

Needle thread tension too high • • • • - ­Stitch le ngth too great • • • • - ­Sewing speed “ house-shaped seam cutting rpm ” too high • • • • - ­Height of the needle plate too high • • • • - ­Pressure foot stroke position too low • • • • - -

Guide Curve

Position and length of the aluminium strips wrong - • - • - •

Trim Blanks

Size o f the blank wrong • • • - - •
Trim incorrectly inserted • • • - - •

• = has an effect o n the edge

- = has no effect on the edge

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6. Synchronizer

With the synchronizer first the 2nd position and then the 1st position
must be set.

The disks 1 a nd 2 of the synchronizer must be set according to the
sketch for the 3rd position ( threading ).

Caution Risk of Injury !

Turnthemainswitchoff.
Set t he synchronizer o nly with the sewing unit turned off.

Setting the 2nd position

–

Turn the handwheel 3 until the thread lever high position is reached.

–

Set d isk 5 accordingly.

Setting the 1st position

–

Turn the handwheel 3 until the guide curve 6 has reached the
position show n in the picture.

–

Set d isk 4 accordingly.

–

Check that both threads are being cut correctly.
Correct the position of the disk if necessary.

Setting the 3rd position

–

Turn the handwheel 3 until the thread lever high position is reached.

–

Set disks 1 and 2 according to the sketch.
The flan k of the 3rd p osition ( disk 2 ) must lie within the
2nd p osition.

1st position = Disk 4
2nd position = Disk 5
3rd positio n = Disk 1 and 2

The setting of the synchronizer can be checked with the program 45.
See Short Description-Microcontrol.

3

4
5

1

2

6

55

7. Pneumatics

The operating pressure for the pneumatic system of the sewing unit is
set at 6 bar by the maintenance unit.

The com pressed air monitor 3 switches the sewing unit off when the
minimum operating pressures drops below 4.2 bar.

Caution Risk of Injury !

Set the compressed air monitor with the sewing unit turned off and
with the greatest possible caution.

–

Pull up the knob 1 and reduce the operating pressure until the
pressure monitor turns the sewing unit off.

The maintenance unit should show a pressure of 4.2 bar.
If the value shown is greater or smaller reset th e pressure monitor
with the screw 2.

1

2

3

56

8. Maintenance

Caution Risk of Injury !

Turnthemainswitchoff.
The mainte nance work on the sewing unit may only be conducted with
the machine turned off !

The maintenance tasks to be conducted by the operating personnel on
the sew ing unit daily or weekly ( cleaning and lubricating ) are
described in Part 1: Ope rating Instructions Chapter 7. They are
included in the following table only for the sake of completeness !

Work to be done Operating Hours

8 40 160 500

Machine Head

Remove lint accumulations in t he area of the needle plate, hook

and thread trimmer ........................................................... ...................... •

Check the oil level in the oilpan .............................................. ............. .... •

Check the oil feed at the window ........................ ................................... .. •

Check hook lubrication ........................................................... ................. •

Check the timing belt ........................................................... ................... •

Drive Unit for the Machine Head and Guide Curve

Check the ventilator wheel on the motor ........................ .......................... •

Check the condition and tension of the V-belt ........................................... •

Guide Curve

Lubricate the curve paths with liquid grease .................................... ......... •

Lubricate the roller ........................................................... ....................... •

Clamping Table

Clean the running surf aces of the clamping table with compressed air ...... •

Clean the ball elements with an oil-soaked rag ............ ............................. •

Check the play of the worm gear .............................. ............................. ... •

Lubricate the curve paths of the guide curves with liquid grease ............... •

Pneumatic System

Check the water level in the pressure regulator ........................................ •

Clean the filter insert in the maintenance unit ........................................... •

Check the system for leaks .......................................... ................. ........... •

57