Duerkopp Adler 506-3 Operating instructions

PDF
Document
506-3
Manual
Instructions, complete
506-3
Overview
Operating table
Operating Instructions
Installation Instructions
Service Instructions
Pneumatic circuit plan
9770 506002
Interconnection-diagram
9890 506003 B
All rights reserved.
Property of D&uuml;rkopp Adler AG and copyrighted. Reproduction or publication of the content in any manner,
even in extracts, without prior written permission of D&uuml;rkopp Adler AG, is prohibited.
Copyright &copy; D&uuml;rkopp Adler AG - 2008
Foreword
This instruction manual is intended to help the user to become familiar
with the machine and take advantage of its application possibilities in
accordance with the recommendations.
The instruction manual contains important information on how to
operate the machine securely, properly and economically. Observation
of the instructions eliminates danger, reduces costs for repair and
down-times, and increases the reliability and life of the machine.
The instruction manual is intended to complement existing national
accident prevention and environment protection regulations.
The instruction manual must always be available at the machine/sewing
unit.
The instruction manual must be read and applied by any person that is
authorized to work on the machine/sewing unit. This means:
–
–
–
Operation, including equipping, troubleshooting during the work
cycle, removing of fabric waste,
Service (maintenance, inspection, repair) and/or
Transport.
The user also has to assure that only authorized personnel work on the
machine.
The user is obliged to check the machine at least once per shift for
apparent damages and to immediatly report any changes (including the
performance in service), which impair the safety.
The user company must ensure that the machine is only operated in
perfect working order.
Never remove or disable any safety devices.
If safety devices need to be removed for equipping, repairing or
maintaining, the safety devices must be remounted directly after
completion of the maintenance and repair work.
Unauthorized modification of the machine rules out liability of the
manufacturer for damage resulting from this.
Observe all safety and danger recommendations on the machine/unit!
The yellow-and-black striped surfaces designate permanend danger
areas, eg danger of squashing, cutting, shearing or collision.
Besides the recommendations in this instruction manual also observe
the general safety and accident prevention regulations!
General safety instructions
The non-observance of the following safety instructions can cause
bodily injuries or damages to the machine.
1. The machine must only be commissioned in full knowledge of the
instruction book and operated by persons with appropriate training.
2. Before putting into service also read the safety rules and
instructions of the motor supplier.
3. The machine must be used only for the purpose intended. Use of
the machine without the safety devices is not permitted. Observe all
the relevant safety regulations.
4. When gauge parts are exchanged (e.g. needle, presser foot, needle
plate, feed dog and bobbin) when threading, when the workplace is
left, and during service work, the machine must be disconnected
from the mains by switching off the master switch or disconnecting
the mains plug.
5. Daily servicing work must be carried out only by appropriately
trained persons.
6. Repairs, conversion and special maintenance work must only be
carried out by technicians or persons with appropriate training.
7. For service or repair work on pneumatic systems, disconnect the
machine from the compressed air supply system (max. 7-10 bar).
Before disconnecting, reduce the pressure of the maintenance unit.
Exceptions to this are only adjustments and functions checks made
by appropriately trained technicians.
8. Work on the electrical equipment must be carried out only by
electricians or appropriately trained persons.
9. Work on parts and systems under electric current is not permitted,
except as specified in regulations DIN VDE 0105.
10. Conversion or changes to the machine must be authorized by us
and made only in adherence to all safety regulations.
11. For repairs, only replacement parts approved by us must be used.
12. Commissioning of the sewing head is prohibited until such time as
the entire sewing unit is found to comply with EC directives.
13. The line cord should be equipped with a country-specific mains
plug. This work must be carried out by appropriately trained
technicians (see paragraph 8).
It is absolutely necessary to respect the safety
instructions marked by these signs.
Danger of bodily injuries !
Please note also the general safety instructions.
Contents
Page:
Preface and General Safety Information
Part 1: Operating Instructions Cl. 506-3
(Edition 10/2008)
1.
1.1
1.2
1.3
Product Description
Description of the Proper Use and Proper Application . . . . . . . . . . . . . . . . . . . . . . . . .
Short Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.
2.1
2.2
2.3
2.4
2.5
Operation
Automatic Sewing Sequence .
Needles and Yarns . . . . . . .
Threading the Needle Thread
Changing the Bobbin . . . . . .
Thread Tension . . . . . . . . .
.
.
.
.
.
9
11
12
14
16
3.
Bobbin winder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
17
4.
4.1
4.2
Maintenance
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
18
20
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5
6
7
1
4
1. Product Description
1.1 Description of the Proper Use and Proper Application
The 506-3 is a robust, heavy-duty, curve-guided single needle
lockstitch short seam unit for seams of stitch type 301.
This short seam unit is designed for use in sewing heavy-weight fabric,
as well as thick and hard leather.
Thick and hard leathers find use in the sewing on of trim pieces, in the
sewing of buckle caps, tabs, suitcases, tarpaulins, knapsacks and
backpacks.
Heavy-weight fabrics are used in the sewing of heavy-duty carrying
belts, car belts, as well as belts for aviation.
Generally only dry sewing material may be worked with this machine.
The material may be no thicker than 16 mm when pressed together by
the lowered clamping feet.
The machine must be operated with eye protection. The information to
be found printed on the yellow sign on the head cover is to be strictly
adhered to.
The seam is generally made with synthetic sewing yarns with a
dimension of 30/3 to 8/3. Those wishing to use other threads must first
evaluate the dangers arising therefrom and, if necessary, take safety
measures.
This heavy short seam unit may only be installed and operated in dry
and clean areas. If the unit is used in other areas, which are not dry and
clean, further, to be agreed upon, measures may become necessary
(see EN 60204-31: 1999).
We, as manufacturer of industrial sewing machines, presume that the
operating personnel working on our products have been given
instruction so that all normal operations and the dangers possibly
arising therefrom can be assumed to be known.
5
1
1.2 Short Description
Uniform Quality
The unit always produces a uniform seam formation.
The high thread tension necessary for the working of heavy materials is
achieved through a hinged thread lever.
Direct Power Transmission
The power transmission from the motor to the arm shaft occurs via a
special V-belt. This results in a particularly strong perforating power for
the sewing of thick materials or multiple layers.
Interchangeable Curve Disks and Material Clamps
The different seam formations are determined by easily
interchangeable curve disks.
The material guidance occurs via a pattern curve with two guide curves.
The difficult and time-consuming turning of heavy pieces of material by
the seamstress is thus unnecessary.
The transmission of the movement to the material clamps occurs via
lever systems.
By changing the lever multiplication the seam formation sizes can be
varied within certain limits.
All curve disks belonging to a stitch number range are interchangeable
among each other.
Large Put-through Area and Large Placement Surface
The large put-through area allows the making of short seams far from
the edge of the material. A rolling-in of flexible sewing material is
possible. The closed width base plate offers a large placement surface
and simplifies the feed.
Pneumatic Clamp Opening
The stroke of the holder clamp is a maximum 20 mm. This stroke allows
the working of almost all sewable materials and leather thicknesses.
Electric Thread Burning Device
The thread separator device separates the needle and underthread by
burning immediately at the top edge of the material. The synthetic
threads are melted together at the ends. The thus created hardening
hinders a loosening of the seam and a unthreading of the needle thread.
Control Unit Quick DA104ED
The complete control of the sewing unit occurs via a Quick control unit.
It assumes the control tasks, monitors the sewing process and
indicates operator errors and malfunctions.
ATTENTION!
These operating instructions give the key functions and describe how
operator-level parameter values are changed by the operator.
For a detailed description of the control unit, please consult the enclosed
current issue of the operating manual of the motor manufacturer.
6
1.3 Technical Data
Sewing area:
Needle system:
maximum 60 x 100 mm
428; 428 Serv Nm 250;
794 (for thick sewing material only)
Needle thickness:
Nm 120 - Nm 280
depending on the type of sewing thread
and the sewing material.
Yarns:
Synthetic yarns
Nm 30/3 - 8/3
Bobbin capacity:
23 m with 18/3 yarn
Stitch type:
Lockstitch type 301
Number of stitches:
1100 / min
Number of stitches per
42, 58, 72 (without gear reducer)
guide curve revolution:
84, 116, 144 (with gear reducer)
Seam formation
72 stitches in 3.5 sec. or
144 stitches in 7 sec.
Looping stroke:
4 mm
Clamp stroke:
max. 20 mm
Sewing material thickness: max. 16 mm
(sewing material pressed
together by the clamp)
Power:
0.55 kW
Motor rpm:
max. 2800 rpm
Operating pressure:
6 bar
Air consumption:
approx. 1,2 NL per work cycle
Motor specifications:
Voltage:
1 x 230V, 50/60Hz
Power:
0,55 kW
Speed:
4000 rpm
Torque:
1.2 Nm
Dimensions:
(H x W x D) 1720 x 1100 x 736 mm
The listed height dimension applies to
the work height of the frame set at the
factory.
Put-through area:
210 x 140 mm
Work height:
760...1060 mm (upper edge of the table
top)
Weight:
160 kg
1
Noise emission
Workspace-specific emission value as per DIN EN ISO 10821:
L pA = 79,4 dB(A), K pA = 0,40 dB(A)
7
Notes:
8
2. Operation
2.1 Automatic Sewing Sequence
2
1
3
1
5
4
ATTENTION !
The starting of a sewing sequence is only possible with the head
cover 1 and cover 2 for the hook area closed.
If the head cover or cover for the hook area is open all functions of the
controls are blocked.
Work procedure (in foot switch mode 1)
– Turn the main switch 3 on.
The clamps are in their upper position.
– Select sewing program.
– Align the sewing material under the clamps.
Depending on the type of work sequence this can occur according
to the markings or the stops mounted specifically for the customer.
Caution Risk of Injury !
Keep hands free of the lowering clamps.
–
–
–
Operate the right foot switch 4.
Both clamps lower simultaneously.
Check the correct alignment of the sewing material.
To correct the sewing material alignment operate the right foot
switch again.
Both clamps rise.
Operate the left foot switch 5.
The automatic sewing sequence starts.
9
–
–
–
–
For a secure sewing-on pull the thread end hanging out of the
needle to the side when starting the first sewing sequence and hold
it tight.
After the first stitches the thread can be released again.
The automatic sewing sequence runs through according to the
selected sewing program.
For an exact description of the different sewing programs see
“Quick User’s manual”.
After the sewing sequence ends the clamps are raised
automatically.
Remove the sewing material.
Quick stop
1
3
2
The safety system of the 506-3 has two different options for the
immediate shut-off of the unit by operator error, needle breakage,
thread breakage etc.:
– Pressing the Stop key 1 on the front panel of the controls.
The sewing sequence is interrupted.
– Pressing the Stop key 2 on the head cover.
The sewing sequence is interrupted.
Bring the sewing machine to its starting position:
– Press button 3 on the sewing head.
The needle moves to its uppermost position.
– Press button 3 on the sewing head again.
The automatic sewing machine slowly returns to its starting
position.
10
2.2 Needles and Yarns
Needle system:
428; 428 Serv Nm 250; 794
(depending on the type of sewing thread and sewing
material used)
Needle thickness: Nm 120 - Nm 280
(depending on the type of sewing thread and sewing
material used)
Yarns:
Synthetic sewing yarns (30/3 to 8/3)
Changing the needle:
2
1
1
A
A
A-A
Caution Risk of Injury !
Turn the main switch off.
Change the needle only with the unit turned off.
–
–
–
–
–
Open the head cover.
Loosen screw 1.
Remove the needle.
Push the new needle into the hole in the needle bar up to the stop.
Hereby align the needle with the furrow 3 to the hook.
The furrow 2 must show to the front (to the seamstress).
Tighten screw 1.
Attention Danger of Breakage!
After a change to a needle with a different needle thickness it is
essential to check the clearances hook point-needle and
driver-needle.
If necessary reset the clearances (see Part 3: Service Instructions).
11
2.3 Threading the Needle Thread
Caution Risk of Injury !
Turn the main switch off.
Thread the needle thread only with the unit turned off.
The threading of the needle thread 18 occurs as shown in the pictures
alongside in increasing numerical order:
– Place the yarn roll on the yarn stand.
– Thread the thread through the holes 1 of the yarn stand.
– Thread the thread through thread guide 2.
– Lead the thread through between the tension disks of the first
needle thread tension 3.
– Thread the thread consecutively through thread guides 4 and 5.
– Guide the thread through between the tension disks of the second
needle thread tension 6.
– Thread the thread consecutively through the hole in the thread pull
7 and thread guide 8.
– Wind the thread from the bottom approx. two times around the
thread roller 9.
– Guide the thread through the thread controller spring 10.
– Guide the thread under the thread guide 12.
– Open the head cover.
– Thread the thread through the hole in the thread lever 13.
– Guide the thread through the hole in the thread control plate 14.
– Insert the thread from the side into the thread gripper 15.
– Thread the thread through the thread guide 17 on the needle bar.
– Thread the thread from the front to the back through the eye of the
needle.
1
18
12
12
11
10
9
8
7
6 5
4
3
2
1
13
14
15
16
17
13
2.4 Changing the Bobbin
3
2
1
4
Remove the bobbin
– Press button 2 on the sewing head or button “
” on the control
unit.
– Hold on to cover 1 and push the locking lever 3 upwards to unbolt
the cover.
– Fold cover 1 forward and down.
ATTENTION !
Cover 1 is monitored by a safety switch.
With the cover open, all functions of the controls are blocked.
Starting the sewing sequence after a change of bobbin is only possible
with the cover closed.
–
–
5
14
To swing the bobbin case 4 out press the ejector lever 5 to the left.
Remove the bobbin from the bobbin case 4.
10
6
9
8
7
1
Inserting a full bobbin
– Place the full bobbin in the bobbin case 6.
Here take care that when thread is being pulled off the bobbin must
turn clockwise (see the arrow direction)!
– Swing in the bobbin case 6.
– Pull the thread through the slit 10 into the opening 9 on the spring 8.
ATTENTION !
A thread sliding out of slit 10 can lead to missing stitches
and needle breakage.
Therefore pull the thread so far through slit 10 until it lies secure in the
opening 9 on the spring 8.
–
–
–
–
Insert the bobbin case.
Pull the thread out of the bobbin case.
Close cover 1.
Press “
” button.
–
The item counter is reset.
Start new sewing run.
15
2.5 Thread Tension
Set the thread tensions appropriate to the yarn types and
thicknesses used so that a clean seam formation results.
Too high thread tensions cause a crimping of the sewing material. Too
low a bobbin thread tension can lead to missing stitches.
Setting the needle thread tension
1
2
–
Set the upper needle thread tension by turning the knurled screw 1
and the lower needle thread tension by turning the knurled screw 2.
Setting the bobbin thread tension
3
4
–
–
–
16
Loosen the fastening screw 3.
Set the bobbin thread tension by turning the setting screw 4.
Tighten the fastening screw 3.
3. Bobbin winder
7
6
5
4
3
8
9
10
11
1
2
1
Reeling on the spool thread
– Place yarn reel on reel stand.
– Thread the thread through the holes 1 in the reel stand.
– Pass the thread through the tension discs of tensioner 2.
– Pass the thread through the tension discs of tensioner 3 of the reel.
– Pass the thread through the slot in guide 4.
– Pass the thread through the hole 7 in the empty reel.
– Place the empty reel on the bobbin shaft 8.
The pin 10 of the bobbin shaft must fit into the hole 7.
– Pass the thread through the star 10 and clamp it in the tensioner 11.
– Use the thread clipper 6 to cut off the end of the thread.
– Raise the thread layer 5.
The bobbin winder is switched on and the winding process begins.
– As soon as the reel is full the thread layer 5 springs back into
position and the winding process is terminated.
17
4. Maintenance
Caution Risk of Injury !
Turn the main switch off.
Maintenance work on the unit may only be conducted with the machine
turned off.
4.1 Cleaning
A clean machine protects against malfunctions !
Daily cleaning:
– Particularly the areas around the needle thread guides 1 and
tensions, thread controller spring and hook 2 are to be cleaned of
sewing dust and lint accumulations (e.g. with a compressed air
gun).
For cleaning the parts attached under the foundation plate tilt the
machine head aside.
2
1
18
–
Check the water level in the pressure regulator.
The water level should not be allowed to rise to the filter insert 3.
After screwing in the drain screw 5 blow the water out of the water
separator 4 under pressure.
Dirt and condensation water are eliminated through the filter insert 3.
Wash out the dirty filter bowl and filter insert with naphtha after a
certain period of operation and blow clean with compressed air.
ATTENTION !
Do not use solvents for washing!
They destroy the filter bowl.
1
3
4
5
Cleaning as required:
–
–
Empty sump pan 1 of the central recirculating-lubrication unit.
Empty collection bag 2 of the thread-suction device and remove any
accumulations of fluff (e.g. with a compressed air gun).
2
1
19
4.2 Lubrication
For lubrication of the machine use only DA-10 lubricating oil.
DA-10 is available from D&Uuml;RKOPP ADLER AG retail outlets.
Check the oil level in the oil reservoir of the oil mister
The run of the barrel shuttle is lubricated and cooled by compressed air
enhanced with oil from the oil mister.
– The oil level in oil reservoir 5 must not fall below the suction tube 4.
– If necessary, top up with oil to the upper edge of the embossed
text 3.
– For topping up screw out the oil filler screw 2.
1
2
3
4
5
Check the feed quantity of the oil mister weekly
– Under operating pressure a drop of oil should drip out of the pipe
under the viewing glass 5 after every 2 to 3 work cycles.
– Regulate the strength of the thus created oil mist at the setting
screw 1.
20
Checking the oil level in the oil reservoir of the central lubrication
unit
The central recirculating-lubrication unit automatically supplies all the
automatic sewing machine’s important lubrication points.
– The oil level in oil reservoir 1 must not fall below the “min” mark.
– If necessary, top up with oil to the “max” mark.
1
1
21
Notes:
22
Contents
Page:
Part 2: Installation Instructions Cl. 506-3
1.
Scope of Delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3
2.
2.1
2.2
2.3
Installation of the Unit
Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Setting the Work Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Attaching the Yarn Stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3
3
4
3.
3.1
Electrical Connection
Connecting the Control Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5
4.
Pneumatic Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6
5.
Oil supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7
2
1. Scope of Delivery
–
–
–
–
–
–
–
–
Frame with sewing drive and table 1100 x 736 mm
Sewing machine with integrated bobbin winder
Quick control unit
Compressed air maintenance unit
Yarn stand
Foot switches
Sewing light
Tools and small parts in the accessories pack
2. Installation of the Unit
ATTENTION !
The unit may only be set up by trained personnel.
Before installing the unit it is essential that all transport fastenings be
removed!
2
2.1 Transport
For in-house transport lift the unit and transport on a suitable wagon
(e.g. lift truck).
2.2 Setting the Work Height
The work height can be set between 76 cm and 106 cm (measured to
the upper edge of the table).
The unit is set at a work height of 82 cm at the factory.
Caution: danger of injury
The automatic sewing machine is very heavy. Once the screws have
been removed the table top may fall at high speed.
When adjusting the working height it is essential to use auxiliary
equipment such as trestles, lifting tackle and the like.
3
1
–
–
Loosen the locking screws 1 on both sides of the frame.
Set the base plate horizontally at the desired work height.
In order to avoid a tilt pull out or push in the base plate uniformly on
both sides.
Tighten the locking screws 1.
–
2.3 Attaching the Yarn Stand
2
2
–
4
Insert the yarn stand 2 into the appropriate hole in the table and
attach with the nuts and washers.
3. Electrical Connection
ATTENTION !
All work on the electrical components of the sewing unit may be
carried out only by electricians or appropriately trained personnel.
The mains plug must be pulled.
The instruction manual of the drive’s manufacturer must
imperatively be respected!
3.1 Connecting the Control Unit
2
1
3
–
2
Screw the operating panel 1 together with its bracket 2 onto the
control unit 3.
5
4. Pneumatic Connection
For the operation of the clamp lifting, thread tension opening, needle
cooling, etc. the unit must be supplied with water-free compressed air.
ATTENTION !
For a flawless functioning of the pneumatic control processes the
compressed air supply must be laid out as follows:
Even at the instant of greatest air consumption the minimum operating
pressure may not fall below 5 bar.
1
2
3
Connecting the compressed air maintenance unit
– Connect the connection hose 3 for the maintenance unit to the
compressed air supply with the enclosed coupling.
Setting the operating pressure
– The operating pressure is 6 bar.
It can be seen on the pressure gauge 2.
– For setting the operating pressure pull knob 1 up and turn.
Turning clockwise
= Increase pressure
Turning counterclockwise
= Decrease pressure
6
5. Oil supply
1
2
3
2
Filling the oil reservoir for shuttle-track lubrication
Only DA-10 lubricating oil may be used to fill the oil reservoir.
DA-10 is available from D&Uuml;RKOPP ADLER AG retail outlets.
– Unscrew oil-filler cap 1.
– Fill the oil reservoir 2 with DA-10 lubricating oil to the upper edge of
the embossed text.
Checking the oil lever in the central recirculating-lubrication unit
Only DA-10 lubricating oil may be used to fill the oil reservoir.
DA-10 is available from D&Uuml;RKOPP ADLER AG retail outlets.
–
Fill the oil reservoir 3 with DA-10 lubricating oil to the “max.” mark.
7
Notes:
8
Contents
Page:
Part 3: Service Instructions Cl. 506-3
1.
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3
2.
2.1
2.2
Removing the top cover and turning over the upper part of the machine
Removing the top cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Turning over the upper part of the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4
6
3.
3.1
3.2
3.3
3.4
3.5
Shuttle, needle bar
Needle bar height. . . . . . . . . . . . . . . . . . . . . . .
Synchronizing the shuttle and needle bar movements .
Shuttle-tip/needle distance . . . . . . . . . . . . . . . . .
Driver/needle distance . . . . . . . . . . . . . . . . . . .
Loop stroke . . . . . . . . . . . . . . . . . . . . . . . . . .
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7
9
10
11
13
4.
Bobbin ejector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
14
5.
5.1
5.2
5.3
5.3.1
5.3.2
5.4
Disc cam
Replacing the disc cam . . . . . . . . . . . . . . .
Fitting the intermediate transmission . . . . . . .
Replacing the worm-gear pair and worm screw .
Fit/Remove the synchronous motor . . . . . . . .
Replacing the worm-gear pair and worm screw .
Worm-screw wheel play . . . . . . . . . . . . . . .
.
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17
20
21
21
23
24
6.
6.1
Shut-down devices
Basic stop position (switch S7). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
27
7.
7.1
7.2
Clamps and table plate
Position of table plate with respect to the needle . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Position of clamps with respect to the table plate. . . . . . . . . . . . . . . . . . . . . . . . . . . .
29
32
8.
Thread advance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
33
9.
Thread-tensioning spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
34
10.
Needle cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
35
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Contents
Page:
11.
11.1
11.2
11.2.1
11.2.2
11.2.3
11.2.4
11.3
11.3.1
11.3.2
11.3.3
11.3.4
11.3.5
Thread-burning device
Thread extractor . . . . . . . . . . . . . . . . . .
Upper burning device . . . . . . . . . . . . . . .
Starting position. . . . . . . . . . . . . . . . . . .
Position of fully-extended burner . . . . . . . .
Adjusting the burner height-stop . . . . . . . . .
Burner angle. . . . . . . . . . . . . . . . . . . . .
Lower burning device . . . . . . . . . . . . . . .
Adjustment preconditions . . . . . . . . . . . . .
Distance between thread extractor and burner
Position of burner when swivelled forwards . .
Burner height . . . . . . . . . . . . . . . . . . . .
Thread-extractor height . . . . . . . . . . . . . .
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36
38
38
39
40
41
42
42
43
43
44
44
12.
Thread-suction device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
45
13.
Bobbin-winder adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
46
14.
V-belt tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
47
2
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1. General
These service instructions describe the adjustment of the automatic
sewing machine in an appropriate order.
CAUTION:
Various adjustments are mutually dependent.
It is therefore essential for adjustments to be carried out in the order
described.
CAUTION:
The activities described in these servicing instructions may be carried
out only by experts or by persons with the appropriate training.
Danger of breakage
It is essential for the adjustments specified in these servicing
instructions to be carried out before the machine is recommissioned
following disassembly.
Never start the machine with the drive motor rotating in the wrong
direction.
A sewing run may not commence unless the head cover and the
shuttle-area cover are closed.
If either of these is open, all control functions are blocked.
3
CAUTION: danger of injury
Prior to all repair, modification and maintenance work the main switch
must be turned off and the machine disconnected from the
compressed-air supply.
Adjustment work and function testing carried out with the machine
running require the utmost care and observance of all safety
precautions.
Setting gauges
We can supply the following setting gauges on request:
Setting gauge
Gauge
Calliper
Gauge
Use
Loop-stroke adjustment
Loop-stroke adjustment
Adjusting the arm-shaft
eccentric (optional)
Order No.
0981 150009
0981 150006
7270 159160
3
2. Removing the arm cover and Turning over the upper part of the machine
2.1 Removing the arm cover
For service work in the interior of the upper part of the machine the
arm cover 3 must be removed.
First the control unit 1 must be swivelled aside and the bobbin-winder
cartridge 2 removed.
3
2
1
5
4
CAUTION: danger of injury
Turn off the main switch and disconnect the machine from the
compressed-air supply.
The arm cover must not be removed until both these steps have been
taken.
Swivelling the control unit aside
– Slightly undo Allen screws 5.
These are accessible through the holes 4 in the casing.
– Carefully swivel the control unit aside.
4
6
2
7
Removing the bobbin-winder cartridge
– Undo fixing screws 6.
– Lift off bobbin-winder cartridge.
3
Removing the arm cover
– Undo arm-cover fixing screws 2.
– Carefully raise the arm cover 2 and fold it back.
– Remove compressed-air hose 7 from the quick-release fastening:
Push the ring 8 to the right and pull the hose out of the
quick-release fastening.
7
8
CAUTION :
The use of force to remove the arm cover may cause damage to the
compressed-air line.
5
2.2 Turning over the upper part of the machine
For service work on the underside of the upper part of the machine the
upper part must be turned over.
CAUTION: danger of injury
Turn off the main switch.
The upper part of the machine must not be turned over unless
the main switch is off.
–
6
Carefully turn over the upper part of the machine until it is
supported by the table-plate prop.
The underside of the upper part of the machine is now accessible
for service work.
3. Shuttle, needle bar
CAUTION:
The adjustments described in chapters 3.1 to 3.4 are mutually
dependent. It is therefore essential for the individual adjustments to be
carried out in the order specified in the service instructions.
3.1 Needle bar height
When the shuttle tip extends 2 mm beyond the right-hand side of the
needle, the eye of the needle must be directly beneath the shuttle tip.
3
2
3
CAUTION: danger of injury
Turn off the main switch.
The needle bar height may only be adjusted with the main switch
turned off.
–
–
–
Turn off the main switch.
Undo screws 2.
Remove clamp 3.
CAUTION: Danger of breakage
It is essential for the clamps to be removed prior to the following
adjustment work.
This prevents the needle from fouling the clamps in the course of
subsequent adjustments.
7
4
2 mm
–
–
–
–
–
8
Turn the handwheel in the direction of rotation until the shuttle tip
extends 2 mm beyond the right-hand side of the needle.
CAUTION:
Care must be taken that the driver touches the shuttle in the
direction of rotation.
Undo locking screws 4.
Adjust the height of the needle bar so that the lower edge of the
shuttle tip just becomes visible in the eye of the needle.
Fully tighten locking screws 4.
Refasten clamp 3 with screws 2.
3.2 Synchronizing the shuttle and needle bar movements
The movement of the shuttle is synchronized with that of the needle
bar by means of the locking pin 1 and gauge 2.
6
1
3
CAUTION: danger of injury
Turn off the main switch.
The shuttle and needle bar movements may only be synchronized with
the main switch switched off.
–
–
–
–
–
Insert locking pin 1 in the hole in the housing of the upper part of the
machine.
Turn the handwheel in the direction of rotation until the locking pin 1
perceptibly engages in the groove of the arm-shaft handle.
Place the gauge 2 on the shaft between the worm-screw wheel 3 and the
eccentric 6 in such a way that the pin 4 points to the eccentric 6.
Push the gauge against the eccentric.
The pin 4 must fit into the hole 5.
The legs 8 of the gauge must lie flat on the unpainted surface of the arm.
7
6
2
5
8
4
Adjustment:
– Remove the top cover.
– Undo the locking screw 7 on the eccentric.
– Turn the handwheel until the pin 4 of the gauge fits into the hole 5
of the eccentric.
– Fully tighten locking screw 7.
– Replace cover.
9
3
3.3 Shuttle-tip/needle distance
The shuttle tip 9 must be as close as possible to the groove of the
needle without touching it.
4
3
5
2
1
6
7
CAUTION: danger of injury
Turn off the main switch.
The shuttle-tip/needle distance may only be adjusted with the main
switch turned off.
–
A
A
8
A-A
Turn the handwheel to bring the shuttle tip 9 close to the needle and check
the position of the shuttle tip with respect to the throat of the needle.
Adjustment:
– Fold the upper part of the machine aside.
– Undo locking screws 6.
– Undo locking screws 4 on adjustment ring 7.
– Extract driver with driver shaft 5 forwards from the shuttle-track
support 3.
– Undo locking screw 1 on the base plate.
– Slightly screw in pressure screw 2.
This opens the base-plate jaws.
– Bring the shuttle tip 8 close to the throat of the needle by axially
shifting the shuttle-track support 3.
The upper surface of the shuttle-track support 3 must be parallel to
the needle plate.
– Screw pressure screw 2 out again.
– Fully tighten locking screw 4 (max. 21 Nm).
– Replace driver with driver shaft 5 in the shuttle-track support 3 and
push back as far as it will go.
– Push adjustment ring 7 as far as it will go against the end of the
shuttle-track support 3.
– Fully tighten locking screws 4.
– Fully tighten locking screws 6.
CAUTION:
It is essential to check the loop-stroke setting.
Fitting a stronger needle has the effect of altering the distance
between the shuttle tip and the needle.
This shuttle-tip/needle distance must be corrected.
10
3.4 Driver/needle distance
The oscillating driver 3 moves the shuttle 1 in the shuttle track.
When the setting of the driver is correct it also acts as a needle guide
in the vertical dimension.
This avoids needle “flutter”, which causes dropped stitches.
The right-hand side of the needle must be parallel to the driver 3 and at
a very small distance from it.
For this purpose the driver 3 must be brought close to the needle.
2
1
3
3
3
4
5
CAUTION: danger of injury
Turn off the main switch.
The driver/needle distance may only be adjusted with the main switch
turned off.
–
–
–
–
–
–
Turn the handwheel to bring the needle to its highest point.
Pull the sprung bolt 4 forwards to unlock the shuttle-track spring 5.
Swivel back the shuttle-track spring 5.
Remove plunger ring 2.
Extract shuttle 1.
To check the setting turn the handwheel to bring the driver 3 close
to the needle.
11
10
9
8
7
6
12
11
Adjustment:
– Fold the upper part of the machine aside.
– Undo locking screws 6.
– Undo locking screws 8 on adjustment ring 9.
– Extract driver with driver shaft 7 forwards from the shuttle-track
support 10.
– Once the driver shaft 7 has been dismantled, remove or add
shims 12. The shims can be found in the accessory kit.
Hint
The use of a smaller needle normally requires a shim to be added
and vice versa.
– Replace driver with driver shaft 7 in the shuttle-track support 10
and push it back as far as it will go.
– Push adjustment ring 8 as far as it will go against the end of the
shuttle-track support 10.
– Fully tighten locking screws 8.
This prevents the driver from being axially shifted.
– Reset the loop stroke (see chapter 3.5).
– Check the setting by turning the belt pulley on the arm shaft. The
right-hand side of the needle must be parallel to the driver and at a
very small distance from it.
If the setting is not correct the adjustment process must be
repeated.
CAUTION:
After adjusting the driver/needle distance it is essential to readjust the
loop stroke as described in chapter 3.5.
12
3.5 Loop stroke
The loop stroke is the travel of the needle bar from its BDC point to the
point at which the shuttle tip 9 is at the same level as the right-hand
side of the needle.
The loop stroke must be 4 mm.
It is set with the gauge 1 (order no. 0981 150012) and block 2
(order no. 0981 150006).
7
8
1
2
3
4
3
CAUTION: danger of injury
Turn off the main switch.
The loop stroke may only be adjusted with the main switch turned off.
9
–
–
–
–
–
–
–
Turn the handwheel to bring the needle bar 4 to its lowest position.
Open the cover.
Press gauge 1 with block 2 upwards against the housing.
Fully tighten locking screw 3 on block 2.
Extract gauge 1.
Turn handwheel in the direction of rotation until the block 2 is in
contact with the housing.
Check whether the shuttle tip 9 is at the same level as the
right-hand side of the needle.
Adjustment:
– Fold the upper part of the machine aside.
– Undo locking screws 8.
– Twist the driver shaft 7 as required.
– Fully tighten locking screws 8.
– Check the driver/needle distance once again and correct it if
necessary (see chapter 3.4).
13
4. Bobbin ejector
The ejector 4 must reliably eject the bobbin. The ejector tip must not
enter the bobbin’s area of movement.
4
1
5
2
5
3
2
3
1
CAUTION: danger of injury
Turn off the main switch.
The ejector may only be adjusted with the main switch turned off.
–
Fold the upper part of the machine aside.
–
–
Undo screw 1.
Twist the ejector 4 on the axle so that the bobbin is reliably ejected
when lever 3 is pressed.
Fully tighten screw 1.
Test by pressing the ejector lever 3.
The bobbin case must automatically swivel out.
–
–
–
–
–
–
–
–
14
Undo locknut on screw 2.
Turn screw 2 to set the end position.
The ejector tip must not enter the bobbin’s area of movement.
Fully tighten locknut on screw 2.
Undo locknut on screw 5.
Turn screw 5 to set the end position.
The ejector must reliably eject the bobbin.
Fully tighten locknut on screw 5.
5. Disc cam
The cam tracks on the inside and outside of the disc cam determine
the transport movement of the clamps.
The inner and outer cam tracks control the longitudinal and transverse
movement of the clamps respectively.
The position of disc cam on the shaft determines clamp-transport
timing.
The disc cam is in its initial position when cam 1 is located immediately
in front of switch S7.
S7
1
3
Disc cam
The various seam (stitch) types are determined by disc cams, which
are easy to replace.
All disc cams with the same stitch number are mutually
interchangeable.
The disc cams are numbered.
The numbers engraved on them have the following meaning:
Example:
116 - 072 .- 1
116
= number of stitches per
disc-cam rotation
072
= stitch type
1
= calculation operation
When converting to a different seam type the clamps belonging to the
installed disc cam must be fitted.
15
Worm-gear set
When converting to a disc cam 4 with a different number of stitches the
appropriate worm-gear set must also be fitted. A worm-gear set
consists of worm drive 2 and worm screw 3.
2
3
4
Intermediate transmission
Fitting the intermediate transmission 6 with idler gear 5 doubles the
number of stitches per disc-cam rotation (transmission ratio 2:1).
without intermediate transmission:
42, 58 and 72 stitches per
disc-cam rotation
(depending on the
worm-gear set)
with intermediate transmission:
84, 116 and 144 stitches per
disc-cam rotation
(depending on the
worm-gear set)
5
16
6
5.1 Replacing the disc cam
1
2
3
6
7
8
4
5
3
CAUTION: danger of injury
Turn off the main switch.
The disc cam may only be replaced with the main switch turned off.
Removing the material clamps and table plate
– Remove the material clamps and table plate 1.
Removing the disc-cam cover
– Remove screws 3.
– Remove disc-cam cover 2.
Removing the disc cam
– Undo screws 6.
– Raise the bracket with drive lever 7 for transverse clamp movement
and push aside.
– Undo nut 5 and screws 8.
– Carefully remove the disc cam 4.
CAUTION:
If converting to a different seam type requires the intermediate
transmission to be installed, this must take place before the new
disc cam is fitted. For the installation of the intermediate
transmission see chapter 5.2.
17
4
5
9
6
7
8
10
11
Fitting new disc cam
– Fit the new disc cam.
CAUTION:
Ensure that the drive lever 9 for the longitudinal clamp movement
engages in the inner cam track of the disc cam.
The claw 11 must exactly fit the shaft edges 10.
Remark:
The illustration shows a machine with the intermediate
transmission fitted.
– Turn the disc cam in the direction of rotation until the claw 11
perceptibly grasps the shaft edges 10.
– Fully tighten nut 5.
– Fit new clamps and new bearing plate.
12
13
–
18
Continue to turn the disc cam in the direction of rotation until the
cam 12 is vertically above the shaft 13.
–
Turn the handwheel in the direction of rotation until the clamps no
longer move.
At this moment, if the setting is correct, the needle is just about to
penetrate the material.
15
16
17
13
12
12
14
8
Adjustment:
– Continue to turn the disc cam in the direction of rotation until the
cam 12 is vertically above the shaft 13.
– Slightly undo the screw 16 on the rider 14.
– Push the rider 14 with screw 15 onto the cam 12 of the
disc cam as far as it will go.
– Fully tighten screw 16.
The position of the disc cam is fixed.
– Undo nut 5.
– Turn the handwheel in the direction of rotation until the needle is
about to penetrate the material.
– In this position insert a screwdriver into the slot 17 and press the
claw 11 onto the shaft edges 8.
– Fully tighten nut 5 and screws 10.
– Push the rider 14 fully to the right and back.
3
CAUTION: Danger of breakage
After the disc cam has been replaced it is essential to check the
following settings:
– the position of the table plate with respect to the needle
(see chapter 7.1)
– the position of the clamps with respect to the table plate
(see chapter 7.2)
19
5.2 Fitting the intermediate transmission
Fitting the intermediate transmission 4 with idler gear 1 doubles the
number of stitches per disc-cam rotation (transmission ratio 2:1).
The intermediate transmission must be fitted before the new disc cam
is installed.
3
4
1
2
5
6
CAUTION: danger of injury
Turn off the main switch.
The intermediate transmission may only be fitted with the main switch
turned off.
–
–
–
–
–
Remove the disc cam as described in chapter 4.1.
Attach the intermediate transmission 4 from outside with screws 3
on the arm of the machine.
Fit bracket 2 and position idler gear 1.
First slightly tighten screws 5.
Complete positioning of idler gear 1 by tightening screw 6.
CAUTION:
Any gear play present is increased by the intermediate transmission.
The idler gear 1 must therefore be exactly in position.
–
–
20
Fully tighten screws 5 and secure with locknuts.
Fit the disc cam as described in chapter 4.1.
5.3 Replacing the worm-gear pair and worm screw
5.3.1
Fit/Remove the synchronous motor
4
3
2
7
1
6
5
CAUTION: danger of injury
Turn off the main switch.
The synchronous motor may only be replaced with the main
switch turned off.
–
–
–
–
–
–
3
Remove proximity switch 4.
Remove handwheel 2.
Unplug connector 3.
Remove cover 1.
Dismantle belt tensioner 6.
Loosen screw 7 and pull out the belt tensioner.
Remove the belt 5.
7
6
5
21
9
8
–
–
11
10
Loosen the screw of the pulley 8 and separate the pulley from the
motor shaft.
Loosen the mounting screws 9 and remove carefully the motor 10
from the fixing plate 11.
Fitting the synchronous motor
– Fit the synchronous motor 10, pulley 8 and the belt again.
22
5.3.2 Replacing the worm-gear pair and worm screw
12
15
14
13
3
CAUTION: danger of injury
Turn off the main switch.
The worm-gear pair and worm screw may only be replaced with the
main switch turned off.
CAUTION: Danger of breakage
It is essential to remove the clamps and needle before replacing the
worm-gear pair and worm screw.
–
–
–
–
–
–
–
–
Remove clamps and needle.
Swivel the control unit aside and remove the arm cover (see
chapter 2).
Remove screw 13 and oil felt.
Loosen locking screws 15 on worm screw 14.
To remove the worm-gear pairs first push worm screw 14 to the
rear in the direction of the arrow.
Undo and remove screws 12 on the bearing.
The fixing screws 12 also act as extractor screws for the
worm-gear pair.
Insert screws 12 into the threaded holes of the bearing.
Carefully extract the worm-gear pair from the housing by evenly
screwing in the extractor screws.
23
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
24
Undo locking screws 16.
Pull the handwheel 17 with belt pulley off the arm shaft.
Undo locking screws 22 on the bearing collar 19.
The locking screws 22 are accessible through the slot 21.
Undo and remove screws 23 on bearing 20.
The fixing screws 23 also act as extractor screws for the bearing.
Insert screws 23 into the threaded holes 18.
Carefully extract the entire bearing 20 from the housing by evenly
screwing in the extractor screws.
Unscrew screws 26 on the eccentric and remove cover plates 25.
Undo cheese-head screw 24 and punch-screw 27.
Press eccentric bearing to the left out of the eccentric and remove
from the arm shaft.
Remove the worm screw 11 from the arm shaft.
Fit new worm screw onto the arm shaft.
Successively replace and secure the eccentric bearing, bearing 20
and handwheel 17.
CAUTION:
Care must be taken that the punch screw engages in the mark on
the shaft, as this ensures that the eccentrics are exactly
positioned.
Fit new worm-gear pair and secure with screws 12.
Push worm screw 11 over the worm gear and adjust worm-gear
play (see chapter 5.4).
Replace all the parts which have been removed (motor, belt, etc ...)
and put them together again.
17
12
16
26
23
3
22
25
21
24
20
11
19
18
27
25
5.4 Worm-gear play
There must be as little as possible gear play between the worm
screw 11 and worm gear.
4
5
11
12
7
6
CAUTION: danger of injury
Turn off the main switch.
The worm-gear play may only be adjusted with the main switch turned
off.
CAUTION:
If an intermediate transmission is fitted it must be removed before this check.
Removing the intermediate transmission
– Remove disc cam as described in chapter 4.1.
– Unscrew screws 4 and remove intermediate transmission 5.
– Unscrew screws 6 and remove bracket 7.
Checking the worm-gear play
– Turn the disc cam to right and left.
A degree of play must be perceptible.
There must be play at all points of the worm gear. Continue to turn
the disc cam and check at all points.
Adjustment:
– Remove arm cover.
– Loosen bracket with oil felt 10 (see page 21).
– Loosen cheese-head screws 12.
– Adjust the gear play by axially shifting the conical worm screw 11
along the arm shaft.
CAUTION:
The first screw 12 of the worm screw - seen in the direction of
rotation - must be on the surface of the arm shaft.
– Tighten locking screws 12.
– Adjust bracket with oil felt to exert slight pressure and tighten.
– Replace arm cover.
– Replace intermediate transmission (see chapter 4.2).
26
6. Shut-down devices
6.1 Basic stop position (switch S7)
Each disc cam (number of stitches) has its own cam 2 with a particular
diameter.
The diameter is such that switch S7 is not operated by the cam one
stitch before or after the initial position.
If the cam is replaced by another with a larger diameter (e.g. in the
event of loss or damage), the following problem may occur:
When the machine is switched on switch S7 is operated, but the disc
cam is one stitch before or after the initial position.
If this happens the control unit does not issue an error message.
3
1
S7
2
CAUTION:
Only the cam 2 belonging to the disc cam, or another cam of the same
diameter, may be used.
The cam may only be wide enough to ensure that switch S7 is not
operated one stitch before or after the initial position.
Before switch S7 is set the setting of the proximity switch must first be
checked.
The following conditions govern initial positioning for reference travel:
– The sewing drive operates until cam 2 operates the switch.
– Once the 1st position has been reached the sewing drive halts in
position 2.
If an error message then appears in the display, the disc cam is
positioned one stitch too far.
The switch S7 must be reset.
27
Setting switch S7
– Loosen screws 1 slightly.
– Push switch S7 upwards so that cam 2 reaches the switch sooner.
– Tighten screws 1.
The outgoing flank of the 1st position must not coincide with the
incoming flank of switch S7.
– Adjust switch S7 as described above for cam 2.
– Check position 1 (thread-lever low point) of the proximity switch
(see chapter 10.5).
– Readjust switch S7 if necessary.
28
7. Clamps and table plate
7.1 Position of table plate with respect to the needle
The transmission of the movement from the disc cam to the clamps
and the table plate is effected by lever systems.
Within certain limits seam-type sizes can be altered by changing the
lever transmission ratios.
The size of the safety gap between the table plate 1 and the needle is
determined by the extent of the transverse and longitudinal movement
of the table plate.
For safety reasons the edges of the hole in the table plate 1 must be at
a constant minimum distance from the needle when it penetrates the
material.
CAUTION: Danger of breakage
If this safety distance is not observed, the needle will strike the table
plate 1.
3
1
3
4
2
5
6
CAUTION: danger of injury
Turn off the main switch.
The safety distance between the table plate 1 and the needle may only
be adjusted with the main switch turned off.
–
–
–
–
–
–
–
7
Remove screws 3 and support 4.
Loosen nut 5 and screws 2.
Remove disc cam 6.
Remove claw 7 from disc cam.
Replace disc cam on the shaft without the claw.
Turn the handwheel to lower the needle.
Turn the disc cam in the direction of rotation and follow the outer
contour of the seam profile, checking that the safety distance
between the table plate 1 and the needle remains constant.
29
a
b
1
5
6
10
9
7
8
Aligning the table plate
a) Transverse:
– Turn the handwheel to lower the needle.
– Turn the disc cam in the direction of rotation until one side of the
table plate (in the transverse direction) reaches the needle.
– Undo nuts 5 and 7.
– Twist the threaded rod 6 to set the distance between the table plate
and the needle.
– Continue to turn the disc cam in the direction of rotation until the
opposite side of the table plate reaches the needle.
– Twist the threaded rod 6 to set the distance between the table plate
and the needle.
– Fully tighten nuts 5 and 7.
b) Longitudinal:
– Turn the disc cam in the direction of rotation until one side of the
table plate (in the longitudinal direction) reaches the needle.
– Slightly undo screw 9.
– Twist the eccentric 10 to set the distance between the table plate
and the needle.
– Continue to turn the disc cam in the direction of rotation until the
opposite side of the table plate reaches the needle.
– Check the distance to the needle.
– Tighten screw 9.
30
5
1
6
10
9
7
8
Setting the extent of the movement of the table plate 1:
3
In the transverse direction:
– Slightly undo nut 8.
– Set the extent of the movement in the transverse direction by
moving the crank along the slot.
– Tighten nut 8.
In the longitudinal direction:
– Undo screw 9.
– Set the extent of the movement in the longitudinal direction by
moving the crank along the slot.
CAUTION:
Do not change the setting of the eccentric 10.
– Tighten screw 9.
7
Replacing parts which have been removed
– Remove the disc cam 6.
– Replace the claw 7.
– Replace the disc cam 6 and secure with screws 2 and nut 5.
– Fit support 4 and secure with screws 3.
6
2
5
3
4
31
7.2 Position of clamps with respect to the table plate
The clamps 2 must be symmetrically aligned with the hole 1 in the table
plate 3.
1
2
3
CAUTION: danger of injury
Turn off the main switch.
Clamps may only be aligned with the main switch turned off.
–
–
–
–
–
–
–
Operate the pressure regulator to lower the operating pressure
to 1 bar.
Lower the clamps.
Slightly undo screws 5 on the clamp bracket 4.
Move the clamp brackets 4 to align clamps 1 and 2 symmetrically
with the hole in the table plate 3.
Fully tighten screws 5.
Raise the clamps.
Restore the operating pressure to 6 bar again.
4
32
5
8. Thread advance
To ensure that the seam is properly started a certain length of upper
thread must be advanced.
The advance takes place on completion of the previous seam with the
clamps still lowered.
Operational sequence
– The upper-thread tensioner opens.
– The burner descends.
– The thread advance 1 advances the required length of thread.
– The thread advance 1 moves back to its initial position.
– The upper-thread tensioner closes.
– The thread extractor draws the upper thread into the burn position.
– The thread is burned through.
– A new sewing run may commence.
Setting
The setting of the thread advance 1 must be such as to ensure that the
seam is properly begun. This will depend on the material being sewn.
CAUTION:
If not enough thread is advanced, it will be under too much tension
when it is burned through and the end of the thread will not “fuse”.
1
2
3
3
Adjustment:
– Set the length of the thread advance by twisting the stop screw 2.
The stop screw 2 limits the stroke of the cylinder 3.
33
9. Thread-tensioning spring
2
3
4
5
1
6
7
Spring travel
When the needle penetrates the material the thread-tensioning
spring 1 must be in contact with the thread-tensioner support 6.
When the eye of the needle enters the material the spring will then be
just free of tension.
Adjustment:
– Undo locking screw 5.
This locking screw is located behind the thread-guide roller 2 under
the arm.
– Twist the thread-tensioner support 6.
– Fully tighten locking screw 5.
Spring tension
The spring must keep the advanced thread under tension until the eye
of the needle penetrates the material.
The spring tension necessary for this depends on the material.
Adjustment:
– Remove retaining ring 3 and shim.
– Remove thread-guide roller 2.
– Slightly undo screw 4.
– Hold the screw 4 in position with a screwdriver to stop it twisting.
– Set the spring tension by twisting the knurled nut 7:
clockwise to increase spring tension
anticlockwise to reduce spring tension.
– Hold the knurled nut 7 in place and fully tighten screw 4.
– Replace thread-guide roller 2.
– Replace shim and retaining ring 3.
34
10. Needle cooling
The needle cooling can be switched from normal to continuous
operation.
In normal operation needle cooling is only activated during sewing.
The air stream emerging from the nozzle 2 must be pointed at the
needle and be of adequate power.
3
1
2
Adjustment:
– Slightly undo locking screw.
– Point the nozzle 2 at the needle.
CAUTION:
Under no circumstances may the air stream emerging from the
nozzle 2 interfere with the burner.
–
–
Tighten locking screw.
Adjust the strength of the air stream with the setting screw 1 of the
throttle valve.
35
11. Thread-burning device
The electrical thread-burning device severs the upper and lower
threads by burning them through.
The end of the upper thread is fused.
The resulting small hardenings prevent the seam from working loose.
To ensure that the thread ends fuse properly it is essential to use only
synthetic threads.
The length of the burned-off lower thread on the material is equal to
the thickness of the needle plate at about 3.5 mm.
11.1 Thread extractor
The thread extractor 3 draws the thread advanced by the thread
advance into the correct position for the severing process.
Swivelling movement
The thread extractor 3 draw forward as much thread as possible.
However, the amount of thread drawn forward must not be so great
that it is not under tension.
CAUTION:
Excessive tension causes the thread to fray when it is severed and
prevents the thread ends from fusing.
1
2
3
Open the head cover.
All control functions are blocked.
– Undo nuts 1.
– Adjust the swivelling movement of the thread extractor 3 by moving
the cylinder suspension up or down.
– Fully tighten nuts 1.
36
Thread-extractor height
With the thread lever in its highest position the thread extractor 3
should pass freely under the needle.
4
–
–
–
3
2
Place material 4 of the maximum permissible thickness (t = 16 mm)
or a shim under the clamps.
Lower clamps.
Turn off the main switch.
CAUTION: danger of injury
Turn off the main switch.
The height of the thread extractor 3 may only be checked with
the main switch turned off.
–
Manually swivel the thread extractor 3 beneath the needle.
The thread extractor 3 must not touch the needle.
Adjustment:
– Undo locking screw 2.
– Adjust height of thread extractor 3.
– Fully tighten locking screw 2.
37
3
11.2 Upper burning device
The correct lateral position of the burner with respect to the thread is
automatically set when the burning device is secured.
11.2.1 Starting position
The burner is in the starting position when the piston rod 4 of the
cylinder 3 is fully retracted.
In this position the thread extractor is located outside the needle-hole
area.
3
4
38
11.2.2 Position of fully-extended burner
When the setting is correct:
– the fully-extended burner must be at a distance of approx. 1 mm
from the clamped material
– the fully-extended burner must be in contact with the thread
positioned by the thread extractor and exert slight pressure on it.
Both these requirements are met if the distance between the upper
edge of the cylinder suspension and the lower edge of the attachment
bracket is 120 mm.
120 mm
1
3
2
–
–
–
–
Open the head cover.
All control functions are blocked.
Loosen locknut 2 on piston rod 1.
Set the distance between the upper edge of the cylinder
suspension and the lower edge of the attachment bracket by
twisting the piston rod 1.
Tighten locknut 2.
39
11.2.3 Adjusting the burner height-stop
1
–
–
–
2
3
Place material 1 of the maximum permissible thickness (t = 16 mm)
or a shim under the clamps.
Lower clamps.
Turn off the main switch.
CAUTION: danger of injury
Turn off the main switch.
The burner height-stop may only be adjusted with the main switch
turned off.
–
–
–
–
–
Remove eye-protection guard after undoing the fixing screws.
The locking screws 3 are freely accessible.
Slightly undo locking screws 3.
Pull the height-stop 2 down until it makes contact with the lowered
clamps.
Fully tighten locking screws 3.
Replace eye protection.
CAUTION: danger of injury
Replace eye-protection guard after completing adjustment work.
40
11.2.4 Burner angle
The burner 4 must be at an angle of approx. 90&deg; to the thread
positioned by the thread extractor 5.
5
1
90&deg;
4
6
3
CAUTION: danger of injury
Turn off the main switch.
The burner angle may only be adjusted with the main switch turned off.
–
–
–
–
–
Remove eye-protection guard 6 after undoing the fixing screws.
The locking screws 1 are freely accessible.
Slightly undo locking screws 1.
Swivel the burner to the correct angle.
Fully tighten locking screws 1.
Replace eye-protection guard 6.
CAUTION: danger of injury
Replace eye-protection guard 6 after completing adjustment work.
41
11.3 Lower burning device
11.3.1 Adjustment preconditions
The setting of the lower burning device must be such that:
– the surface 2 on the shuttle-track support 1 must be parallel to the
throat plate.
1
2
42
11.3.2 Distance between thread extractor and burner
The distance between the thread extractor 2 and the burner 1 must be
as small as possible in the front area.
1
2
4
5
3
3
CAUTION: danger of injury
Turn off the main switch.
The distance between the thread extractor 2 and the burner 1 may only
be adjusted with the main switch turned off.
–
–
–
–
Fold the upper part of the machine aside.
Slightly undo screws 3.
Set the correct distance by moving the thread extractors 2.
Fully tighten screws 3.
11.3.3 Position of burner when swivelled forwards
The left-hand side of the burner 1 must be on a level with the outer
edge of the needle-hole sleeve 6.
CAUTION: danger of injury
Turn off the main switch.
The position of the burner 1 may only be adjusted with the main switch
turned off.
–
–
–
Undo locknut 5.
Set the position of the burner by twisting the stop-screw 4.
Fully tighten locknut 5.
43
11.3.4 Burner height
When swivelled forwards the burner 1 exert slight pressure on the
needle-hole sleeve 6.
In the starting position the burner 1 must not touch any other part.
6
2
7
1
CAUTION: danger of injury
Turn off the main switch.
The height of the burner 1 may only be adjusted with the main switch
turned off.
Adjustment:
– Bend the burner 1 as required.
11.3.5 Thread-extractor height
The distance between the thread extractor 2 and the thread-guide
plate 7 must be as small as possible.
The resulting slanting position of the threads favors the severing
process.
However, the lower thread must not be jammed between the thread
extractor 2 and the thread-guide plate 7.
CAUTION: danger of injury
Turn off the main switch.
The height of the thread extractor 1 may only be adjusted with the main
switch turned off.
Adjustment:
– Bend the thread extractor 1 downwards as required.
44
12. Thread-suction device
The thread-suction device 1 picks up the needle thread and holds it
fast at the beginning of the seam.
This prevents the needle thread from slipping out of the needle when
sewing begins.
3
1
2
3
CAUTION: danger of injury
Turn off the main switch.
The position of the thread-suction device may only be adjusted with the
main switch turned off.
CAUTION: Danger of breakage
Ensure that the thread-suction device is at the proper distance from the
clamp.
–
–
–
Undo screws 2 and 3.
Adjust the thread-suction device so that the starting and needle
threads are reliably picked up.
Retighten screws 2 and 3.
45
13. Bobbin-winder adjustment
The setting of the spring 1 of the thread layer 4 must be such that the
thread layer switches off when the bobbin is full.
The thread to be wound on should be tightly pre-tensioned. Adjust the
two tensioners 5 accordingly.
1
4
5
2
3
CAUTION: danger of injury
Turn off the main switch.
The bobbin winder may only be adjusted with the main switch
turned off.
Adjustment:
– Undo locknut 2.
– Turn the screw 3 to adjust the spring of the thread layer 4
accordingly.
– Tighten locknut 2.
CAUTION:
The bobbin winder is fitted with a thermal switch.
In the event of overheating the power is interrupted. After cooling-off
the winding process is automatically resumed.
46
14. V-belt tension
4
3
2
1
6
5
CAUTION: danger of injury
Turn off the main switch.
The V-belt tension may only be adjusted with the main switch
turned off.
–
–
–
–
–
–
–
–
3
Remove proximity switch 4.
Remove handwheel 2.
Unplug connector 3.
Remove cover 1.
Loosen screw 5 slightly.
Stretch the belt via screw 6.
Tighten screw 5 again.
Fit the cover, connector, handwheel, proximity switch again.
47
48
M1.1
A2
Extern
M1.2
M
Z
1
2
1
2
3
4
X4
X3
OD/ABSE
OD/ABSE
OD/FL
OD/SE
Optional equipment
8A
8A
4A
4A
OC 500mA
OD/FL 4A
OC 500mA
OD/FL 4A
OD/SE 4A
OD/SE 4A
OC 500mA
OC 500mA
SYMA
OC 500mA
OC 500mA
OC 500mA
Out_A9
Out_A5
Out_A11
Out_A6
+24V
Out_A7
Out_A8
Out_A4
Out_A1
X5
29
30
31
32
33
34
35
36
37
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
X2
37-pol
LED 1
ws
bn
A1
LED 2
gn
ge
gr
rs
analog
+5V
analog
0V
IN_E2
IN_E1
IN_E3
IN_E4
IN_E5
IN_E6
IN_E7
IN_E8
IN_E9
IN_10
+15V
+24V
+24V
+24V
GND
Out_A15
Out_A10
Out____
Out_A12
Out_A13
Out_A14
+24V
Out_A3
Out_A2
controlbox Quick DA104ED
X2
X1
gr
gr
X1
Steuerung Quick DA104ED
rt
sw
Zusatzeinrichtung
9870 506303 L019
sewing light
Motor
M1
LED 3W
N&auml;hleuchte
H1
bn
bl
gnge
gr
sw
rtbl
gnbl
gebl
gnrt
wsgr
ge
wsbl
gegr
bnbl
bnrt
gert
gers
bnsw
rsbn
wssw
grgn
wsrs
wsrt
grbn
gnsw
gesw
wsgn
gebn
rsgn
bl
bngn
gn
wsge
ws
grrs
vi
rt
bn
rs
T1
c
b
a
T2
L010
Datum 24.04.08
Bearb. Cz
Gepr&uuml;ft
Name Norm
9870 506303 2x L008
Brenner f&uuml;r Oberfaden
Burner for needle thread
A4
A3
Burner heating on
1 A8
ws 1
V1
K1
Opto-elektr.
Relais
X1
C1
R1
100R
1V
L010
F2
F1,6A
Leiterplatte k. 9850 506017
Junction box at sewing head /X2
6
/2.7
Verteiler am Oberteil /X2
X21/Inputs
mains plug
Netzstecker
/2.2
X21/Eing&auml;nge
bn
L1
bl
N
PE gnge
X0
PCB
Brennerheizung ein
2 +24V
3
bn 2
3
X8 X3
9870 506303 L020
230V
+10% -20%
50/60Hz
9870 001020
Leitung k
9870 506302 L001
&Auml;nderung Datum
9850 001083
M0,63A
F1
IN:
190-240V
50/60Hz
10VA
OUT:
LED1: 24V/70mA
LED2: 400mA
3W
5
bn
1
4
1
2
1
bn
3
3
7
2
1
1
L011
2
2
X2 X7
bl
bn
gnge
0068/08
Freigabe
Teilefamilie
8
Z
Verteiler
X4
10
Blatt
1/4
Spuler 0504 170854
bobbin winder
M2
1~
M
Bauschaltplan
9890 506003 B
Hook monitoring /X1
L
X3
Leitung k
9840 503001
Leitung k
9870 001021
junction box
Greifer&uuml;berwachung /X1
X5
9
9870 506302 L003
9870 506302 L004
Netzspannungsteil
N&auml;hantrieb QE5540/DA104ED
506-3
gnge
bl
bn
gnge
bl
bn
gnge
bl
bn
X6 X6
Brenner f&uuml;r Unterfaden
Burner for bobbin thread
9870 506303
L007
L006
L005
X41-X42/outputs
T2
L2
PE
T1
L1
Q0
main switch
Hauptschalter
7
/3.2
X41-X42/Ausg&auml;nge
gnge
bl
bn
bl
bn
9870 506303 2x L009
gnge
1
bn
bl
gnge
L
N
PE
/4.1
2
5
bn
bl
gnge
L
N
PE
bn
bl
bn
bl
gnge
L
N
PE
N
L
U
PE
N
PE
V
PE
1
Z
X1
Optional equipment
Zusatzeinrichtung
X2/controlbox
/1.5
X2/Steuerung
X2
Leiterplatte k.
9850 506011
2
9870 506302 L001
X21
9850 805006
3
15
wsge
E4
c
b
a
8
rt
E8
6
2
12
1
10
16
11
rs
bn
rtbl
ws
vi
gebn
grrs
E10
E9
E5
E7
+24V
E6
Verteiler am Oberteil
13
14
11
12
9
10
7
8
5
6
1
2
3
4
X1
13
14
12
11
9
10
7
8
5
6
1
2
3
4
X2
bn
ws
Datum 24.04.08
Bearb. Cz
Gepr&uuml;ft
Name Norm
J2 and J4 drilled out
&Auml;nderung Datum
5
bn
ws
ge
gn
ws
bn
bn
ws
ws
bn
bn
ws
bn
ws
bn
ws
gn
ws
bn
Junction box at sewing head
J2 und J4 aufgebohrt
3
gn
9
E3
sw
5
4
ge
A8
gr
14
13
7
bngn
wsgn
bl
X21
(16pol.)
E1
+24V
E2
A5
4
J2
J3
J4
+24V
J1
J5
J6
J7
J8
J9
+24V
Taster k
9880 506005
9870 506303 L018
1
2
bn 1
ws 2
X25
(2pol.)
bn 1
ws 2
X26
(2pol.)
ge
gn
X24
ws
bn
gn
(2pol.)
0068/08
Freigabe
Teilefamilie
9870 506303 L016
9870 506303 L015
9870 506303 L014
9870 506020 L056
9870 506306 L017
Z
9870 506303 L020
9870 506303 L013
6
1
2
3
bn
bl
bn
bl
bn
bl
(*1)
(*1)
(*1)
/1.5
ws
bn
gn
Relais
S4.1
2
S4
S8
ws
bn
bn
ws
S7
S6
S5
506-3
0
2
1
S3
1
S2
S1
2
S4
1
S4.1
S4.2
Grundstellung
Basic position
Rechte Klammer oben
Right clamp up
Linke Klammer oben
Left clamp up
Spulenwechsel
Bobbin change
(*1)
Induktivgeber k
13
10
9815 710103
X2
+24V
A8
A6
Bauschaltplan
9890 506003 B
Kopfdeckelkontrolle
Head cover control
Oberteil- und Greiferklappenkontrolle
10
X2
Z
Ausgang 8
output 8
Fu&szlig;schalter rechts
Foot switch right
Fu&szlig;schalter links
Foot switch left
9
Sewing head- and hook cover controll
Stopp
Stop
bobbin rotation monitoring
/4.1
Spulen-Dreh&uuml;berwachung
Control box
Steuerung k. 9850 506014
X8/Burner heating on
S4.2
bn
ws
bn
ws
+24V
E2
+24V
E1
X8/Brennerheizung ein
gn
ws
bn
bn
ws
ws
bn
Foot switch
Fu&szlig;schalter k 9880 506301
8
Eing&auml;nge + Ausgang 8
N&auml;hantrieb QE5540/DA104ED
X55
X23
7
- Start interlock -
14
13
12
11
10
9
8
7
6
5
4
3
2
1
- Laufsperre -
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Blatt
2/4
Z
Optional equipment
Zusatzeinrichtung
X2/control box
/1.6
X2/Steuerung
9870 506302 L001
9870 506303 L012
3
c
b
a
6
7
8
9
gnrt
gert
gnsw
gesw
A14
A15
A10
Datum 24.04.08
Bearb. Cz
Gepr&uuml;ft
Name Norm
5
gebl
+24V
2
4
gers
gnbl
X42
(10pol.)
12
9
wssw
A2
gegr
8
bnrt
A13
A1
7
wsrt
A11
11
6
bnbl
A12
grgn
5
wsbl
A4
A9
4
rsbn
A2
10
3
wsrs
A5
bnsw
2
grbn
A6
A3
13
rsgn
1
+24V
X41
wsgr
(14pol.)
5
A7
&Auml;nderung Datum
4
7
6
5
4
3
2
12
11
10
9
8
7
6
5
4
3
2
1
Y10
Y15
Y14
Y1
Y9
Y3
Y2.2
Y13
Y11
Y12
Y4
Y2.1
Y5
Y6
Y7
Stempel
die
Reserve
Reserve
Reserve
Reserve
0068/08
Freigabe
Teilefamilie
Z
Faden ansaugen (s6)
Thread suction
Fadenspannung l&ouml;sen (s3)
Releasing thread tension
Oberfadenklemme (s5)
Needle thread clamp
Greiferschmierung (s28)
Hook lubrication
Mowe burner forward
Brenner vor (s26)
Brenner absenken (s22)
Lower burner
Fadenwischer vor (s20)
Thread wiper forward
Unterfadenklemme (s19)
Bobbin thread clamp
Nadelk&uuml;hlung (s18)
Needle cooler
Faden ziehen (s4)
Pull thread
Klammer rechts (s2)
Right clamp
Klammer links (s1)
Left clamp
6
7
506-3
Ausg&auml;nge
N&auml;hantrieb QE5540/DA104ED
A9
Z
A7
8
X41 1
12 11 10 9 8 7 6 5 4 3 2
1
Junction box at sewing head
Verteiler am Oberteil
9
Leiterplatte k. 9850 001016
1
X42
2 3 4 5 6 7 8
Bauschaltplan
9890 506003 B
Z
Z
normally open (NO)
Leiterplatte k. 9850 001038
** stromlos offen
**
2
**
Y10
1
Y1
Y9
Y3
Y2.2
Y13
Y11
Y12
Y4
Y2.1
Y5
Y6
Y7
10
Blatt
3/4
Z
junction box X2
/2.8
Verteiler X2
junction box X5
/1.9
Verteiler X5
1
Optional equipment
Zusatzeinrichtung
9870 506020 L56
X55
(8pol.)
ws
bn
9870 506019 L51
2
1
2
A8
PCB
bn
bl
230V~
9850 506013 S
S8
K1
X1
c
b
a
1
2
3
4
5
6
1
2
1
2
3
4
5
4
X54
(7pol.)
X53
(3pol.)
X52
(6pol.)
&Auml;nderung Datum
Leiterplatte k 9850 506013
Control box
Steuerung k. 9850 506014
Hook monitoring
Z
Greifer&uuml;berwachung 0506 590014
3
rs
ge
gr
bn
gn
ws
rot
V52
gr&uuml;n
V51
S52
S51
S54
S53
Taster k. 9880 506006
9870 506020 L57
9815 925007
Datum 24.04.08
Bearb. Cz
Gepr&uuml;ft
Name Norm
ws
bn
gn
ge
gr
rs
bl
bn
ws
bn
gn
ge
gr
5
0068/08
Freigabe
Teilefamilie
Fehler
Error
Ready
Betriebsbereit
Error receipt
Fehlerquittung
Error receipt / test
Fehlerquittung/Test
Scan position
Abtastposition
Spulenabtastung
Bobbin scanner
6
7
Leiterplatte k
Fu&szlig;schalter k
Leiterplatte k
Steuerung k
A5
A6
A7
A8
N&auml;hleuchte
N&auml;hmotor
Positionsgeber
Y-Adapter
Spuler k
Netzleitung
H1
M1
M1.1
M1.2
M2
Drucktaster
Mikroschalter
Induktivgeber
Induktivgeber
Induktivgeber
Netzteil
Transformator
Stecker, Netz
Geh&auml;use
Klemmleiste
S4.1
S4.2
S5
S6
S7
T1
T2
X0
X5
506-3
Taste
Kontaktelement
S4
Zusatzeinrichtung, Teileliste
N&auml;hantrieb QE5540/DA104ED
Taster k.
S3
Schalter, Netz
Sicherung
F2
Q0
Sicherung
F1
Leiterplatte k
Transformator k Brenner
A4
A9
Leiterplatte k
A3
Teilenummer
9850 001016
9880 506301
9850 506011
9870 506304
9850 506017
9800 350003
24VDC/5VA
9830 200710
9825 570004
9825 190104
9810 810002
9850 001083
9815 710103
9815 710103
9815 710103
9815 510001
0999 202226
9815 110025
9815 110026
9880 506005
9815 580001
0504 170854
9840 503001
9800 350004
9800 347002
9800 150010
9822 560000
10
Z
Z
Z
Blatt
4/4
Bemerkung
Bauschaltplan
9890 506003 B
M8 Ltg.110mm
M8 Ltg.110mm
M8 Ltg.110mm
MZD1021306
1S+1&Ouml;
3x0,75
Quick
Quick PD3
Quick QE5540
LED
F1,6A/250V 5x20mm 9825 810213
Greifer&uuml;ber0506 590014
wachung
Magnetventile f&uuml;r
9850 001038
Erweiterungen
M0,63/250V 5X20mm 9825 810308
Magnetventile
2-fach
Verteiler
Brenner
Quick Eco Topp
Bedienfeld
A2
9
Quick DA104ED
9800 351008
T8,0A/250V 5x20mm 9825 810418
Abmessung
Steuerger&auml;t
Sicherung
Benennung
A1
Kurzzeichen
8
Subject to design changes - Part of the machines shown with additional equipment - Printed in
Germany &copy; D&uuml;rkopp Adler AG - Original Instructions - 0791 506010 - 03.0 - 10/2018
D&Uuml;RKOPP ADLER AG
Potsdamer Str. 190
33719 Bielefeld
Germany
Phone: +49 (0) 521 925 00
E-Mail: [email protected]
www.duerkopp-adler.com
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