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  9. Duerkopp Adler 1180i-5 Troubleshooting guide

Duerkopp Adler 1180i-5 Troubleshooting guide

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Instructions for service
1180i - 5
Minerva Boskovice, a.s., Sokolská 60, CZ - 680 17 Boskovice
Tel.: +4 0-516-453434, 453433, 494111 Fax: +4 0-516-45 165 http://www.minerva-boskovice.com
Edition: 09/ 004 Printed in Czech Republic S735 000635
CONTENTS:
1. General safety instructions ............................................................................................................................................................. 1
2. Introduction .......................................................................................................................................................................... 1
3. Head of the sewing machine ................................................................................................................................................ 2
3. 1 Hook and hook box .................................................................................................................................................................. 2
3.1.1 Description
3.1.2 Height setting of the hook
3.1.3 Setting the distance of the hook from the needle
3.1.4 Angular setting of the hook (timing)
3.1. Protection of the needle and of the hook point
3.1.6 Setting of the bobbin case opener
3.1.7 Setting the regulation of the hook lubrication
3.1.8 Replacement of the hook
3.1.9 Setting the gear
3.1.10 Dismantling of the hook box
3.2 Needle and thread mechanism ...............................................................................................................................................
3.2.1 Description
3.2.2 To check the handwheel angular adjustment
3.2.3 Height setting of the needle bar
3.2.4 Angular setting of the pin of the thread mechanism
3.2. Side setting of the needle bar holder
3.2.6 Setting the needle (the needle bar holder) in the direction of sewing
3.3 Throat plate ............................................................................................................................................................................ 7
3.3.1 Description
3.3.2 Mounting and removing the throat plate and its insert
3.3.3 Setting the throat plate and its insert
3.4 Thread tensioners and limiter ................................................................................................................................. 8
3.4.1 Description
3.4.2 Setting the tension of main and auxiliary tensioners
3.4.3 Setting the tensioning mechanisms of the main tensioners
3.4.4 Setting the adapting spring
3.4. Setting the thread limiter
3.5 Feeding mechanism of the needle feed and of the lo er feed heel ........................................................................ 10
3. .1 Description
3. .2 Stitch length mechanism
3. .2.1 Setting the upper eccentric
3. .2.2 Setting the prop
3. .2.3 a Forward and rearward stitch length distribution (rough)
3. .2.3 b Forward and rearward stitch length distribution (fine)
3. .2.4 Setting of the control knob (including the stitch length limitation)
3. .3 Lower feed wheel
3. .3.1 Feeding clutches
3. .3.1.1 Description
3. .3.1.2 Setting the lever of the second step of feeding(angle, position)
3. .3.1.3 Setting of the lower eccentric
3. .3.1.4 Setting the engagement and disengagement of the clutches
3. .3.2 Wheel feeder and its post
3. .3.2.1 Height setting of the feeder
3. .3.2.2 Replacement of the feeder
3. .4 Setting the top roller (pressing force, height)
3.6 Feeding mechanism of the top roller ....................................................................................................................1
3.6.1 Description
3.6.2 Side setting of the indented lower pulley
3.6.3 Side setting of the indented upper pulley
3.6.4 Setting the tensioning roller
3.6. Replacement of the indented belt
3.6.6 Top roller
3.6.6.1 Selection of the top roller diameter
3.6.6.2 Forward, rearward and side setting
3.6.6.3 Setting the gear clearance and in the mounting of the top roller
3.6.6.4 Replacement of the top roller
3.7 Setting the presser foot lift .................................................................................................................................................. 18
3.8 Bobbin inder ....................................................................................................................................................................... 19
3.8.1 Description
3.8.2 Setting the bobbin winder stop
3.8.3 Setting the friction gear
3.9 Safety clutch .......................................................................................................................................................................... 20
3.9.1 Description
3.9.2 Setting the disengaging moment
3.10 Indented belt transmission ................................................................................................................................................. 20
3.10.1 Setting the tensioning roller of the indented belt
3.10.2 Replacing the indented belt
3.11 V-belt, motor - head .............................................................................................................................................................. 21
3.11.1 Tensioning
3.11.2 Replacing the V-Belt
3.12 Driving toothed belt ............................................................................................................................................................... 21
3.12.1 To exchange the driving toothed belt
3.13 Lubrication .............................................................................................................................................................................. 22
3.13.1 Description
3.13.2 Refilling oil
3.13.3 Multiple oil use
4. Thread trimming ................................................................................................................................................................................ 23
4.1 Description of the trimming mechanism
4.2 Setting the pickup roller
4.3 Setting the cam
4.4 Setting the fork
4. Setting the moving knife
4.6 Setting the fixed knife
4.7 Setting the retaining spring of the hook thread
4.8 Setting switching of the electromagnets
5. Lifting the to roller by electromagnet ....................................................................................................................................... 2
.1 Description
.2 Setting the electromagnet pin
.3 Setting the electromagnet current
.4 Assembly of the top roller lifting electromagnet
6. Backtacking using electromagnet ................................................................................................................................................. 26
6.1 Description
6.2 Electromagnet height setting
6.3 Setting the position of push-buttons
6.4 Change of the function of push-buttons
7. Connecting the electric elements on the machine head ......................................................................................................... 27
8. Drive, control anel, osition sensor ......................................................................................................................................... 27
9. Maintenance (table of o erations) ............................................................................................................................................... 28
10. Setting the machine according to the sewing category ............................................................................................................ 28
10.1 Introduction
10.2 Table of setting the machine according to the sewing category
1
1. General safety instructions
The non-observance of the following safety instructions can cause bodily injuries or damages to the machine.
1. The machine must only be commissioned in full knowledge of the instruction book and operated by persons with appropriate
training.
2. Before putting into service also read the safety rules and instructions of the motor supplier.
. The machine must be used only for the purpose intended. Use of the machine without the safety devices is not permitted.
Observe all the relevant safety regulations.
4. When gauge parts are exchanged (e.g. needle, top roller, needle plate, feed dog and bobbin) when treading, when the
workplace is left, and during service work, the machine must be disconnected from the mains by switching off the master
switch or disconnecting the mains plug.
5. Daily servicing work must be carried out only by appropriately trained persons.
6. Repairs, conversion and special maintenance work must only be carried out by technicians or persons with appropriate
training.
7. For service or repair work on pneumatic systems the machine must be disconnected from the compressed air supply system.
Exceptions to this are only adjustments and function checks made by appropriately trained technicians.
8. Work on the electrical equipment must be carried out only by electricians or appropriately trained persons.
9. Work on parts and systems under electric current is not permitted, except as specified in regulations DIN VDE 0105.
10. Conversions or changes to the machine must be authorized by us and made only in adherence to all safety regulations.
11. For repairs, only replacement parts approved by us must be used.
12. Commissioning of the sewing head is prohibited until such time as the entire sewing unit is found to comply with EC
directives.
It is absolutely necessary to respect the safety instructions marked by these signs.
Danger of bodily injuries !
Please note also the general safety instructions.
IMPORTA T WAR I G
In spite of all safety measures made on the machines, inappropriate actions of the operator may lead to dangerous situations. In
industrial sewing machines, attention should be paid to the following still remaining possible sources of injury:
1. Moving sewing needle
- risk of injury when sewing with raised pressure foot or top roller, because the finger guard is then positioned too high,
- risk of injury when inadvertently threading down of the motor threadle.
2. Moving thread take-up lever
- risk of injury when inadvertently or intentionally inserting the finger(s) between the thread take-up lever and its guard.
. Moving pressure member
- risk of injury when holding sewn work in immediate vicinity of the pressure member and beginning to insert under the
pressure member a considerably thicker sewn work portion,
- risk of injury when sinking the pressure member.
4. When switched off, the clutch motor slows down by inertia but would be reactivated by an accidental treading down of the
motor treadle. To avoid such risk, it is advised to hold the handwheel by hand and slightly to depress the motor treadle.
2. Introduction
This service book contains instruction for regulating the mechanisms of the sewing machine head.
The instructions for use and for putting the machine into operation and for the control of the stopmotor are not included in this
service book, but they are supplied as separate publications.
This service book is universal for all subclasses of the machine - it contains setting procedures for all elements which may be
placed on the machine of the given class. When the supplied subclass of this machine does not include some element, then it is
possible to leave out the respective parts of the instructions. The optional equipments of the machine and the respective
configurations of the subclasses of the machine are given in the operating instructions.
This sewing machine disposes of a large extent of its use. The machine should be set with respect to the parameters of the sewn
material, the sewing thread etc. The setting for the individual categories is given in the chapter 11.2.
For setting the machine, simple setting aids are used which are included in the accessory of the machine. Besides these aids,
universal measuring devices are used, such as slide calliper, feeler gauges and dynamometer for measuring the thread tension.
2
3. Head of the sewing machine
3.1 Hook and the hook box
3.1.1 Description
The hook (1) is mounted on the shaft (2) and is driven by the
gear (3) from the shaft (4).
The shaft of the hook (2) is mounted on the top in a sliding
bearing and, on the bottom, in a needle bearing.
The hook is provided ith a lever (6) hich is tilted hen
removing the bobbin (7). The protecting sheet (8) protects
against the collision of the needle ith the hook point. The
bobbin case opener (9) is driven by the eccentric (10) on the
shaft (2).
The lubricating tube (11), on hich a lubricating ick is
fastened in the tube (12), feeds oil for lubricating the sliding
bearing (5) of the eccentric (10) and the hook path.
The scre s (13) serve for taking up the clearance of the gear.
The scre s (14) fasten the hook box to the bedplate.
The lubricating felt (15) is connected by the ick (16) ith the
main lubricating system and serves for lubricating the gear
(3).
3.1.2 Height setting of the hook
The designated distance A should be 5.3 mm.
Caution! Danger of injur !
S itch off the main s itch ! Before starting the
setting operation, ait until the motor stops!
- Remove the slide plate (1).
- Loosen both scre s (2).
- By turning the scre s (3 and 4), set the required distanceA.
After having set it, tighten carefully the scre s. For setting
up use the setting gauge (7) as per the repective figure.
- By axial shifting of the gear heel (5), set the axial clearance
in such a ay that this clearance is the least possible, but
sufficient for turning easily the hook.
- Tighten carefully the scre s (2). Caution ! One of these
scre s must bear on the flat of the shaft 6).
3.1.3 Setting the distance of the hook from
the needle
The hook point (1) is set up to the maximum distance of
0.1 mm from the bottom of the needle recess (2). For the
se ing categories 1 and 2, the needle size 100 is set, for the
se ing categories 3 and 4, it is the needle size 160.
Caution! Danger of injur !
S itch off the main s itch ! Before starting the
setting operation, ait until the motor stops!
- Shift the plate (3).
- Loosen only one scre (4).
- Loosen the scre s (5) and tighten them only slightly.
- Shift the hook box (6) at the determined distance bet een
the needle and the hook point.
- Tighten the scre (4).
- Tighten duly the scre s (5).
- Check up the setting ith magnifying glass and proceed to
the eventual correction of setting.
Caution!
When changing substantially the se ing catego-
ry, the protecting sheet of the hook (7) should
be set up.
1
7
max. 0,1
2
1
3
15
4
5
9
7
8
6
11
12
14
10
16
13
2
14
A
3
4
6
3
5
4
4
5
5
2
6
7
3
3.1.4 Angular setting of the hook (timing)
The hook is to be angularly set in such a ay that the hook
point (1) is opposite the needle at the moment, hen the
needle shifts by 2.5 mm from its bottom dead center. This
corresponds to the 2O5° on the scale of the hand heel (3).
Caution! Danger of injur !
S itch off the main s itch! Before starting the
setting operation, ait until the motor stops!
- Remove the throat plate.
- Turn the hand heel (3) to the 2O5° and fix it ith the scre
(4) hich is component part ot the accessory of the machine
(tighten it carefully).
- Loosen the scre s (5) of heel (6).
- Turn the hook into the required position.
- Set the gearing of the heel (6) at the centre of the heel
(7).
- Tighten to the maximum the scre s (5).
3.1.5 Protection of the needle and of the hook point
The protecting sheet (1) is to be set up in such a ay that the
clearance bet een the protecting sheet and the needle (2) is
the least possible.
Caution ! Danger of injur !
S itch off the main s itch! Before starting the
setting operation, ait until the motor stops!
- Remove the throat plate and the movable trimming knife.
- Unscre the scre (3).
- Put the scre driver into the hole of the scre (3) and, using
the regulating scre , set up the required clearance bet een
the needle (2) and the protecting sheet (1). When turning to
the right, the protecting sheet shifts out from the groo e
and inversely.
- Check up the protecting effect in pushing against the needle
in The sense of the arro (5). The hook point must not
catch the needle. If so, set up the protecting effect, correct
eventually the setting of the distance of the hook point
from the needle according to the paragraph 3.1.3.
- Scre in the scre (3).
3.1.6 Setting of the bobbin case opener
The bobbin case opener (1) is to be set in such a ay that, at
the moment hen the opener is in its dead centre, there ould
be a clearance A bet een the opener (1) and the projection
(2), hereas the finger (3) bears on the projection (4), A =
0.7 mm for the se ing category 1 and 2, A = 0.3 mm for the
se ing category 3 and 4.
Caution ! Danger of injur !
S itch off the main s itch! Before starting the
setting operation, ait until the motor stops!
- Remove the slide plate.
- On the hand heel (5), set the angle of 295° (the hook is in
its dead centre).
- Loosen the scre (6).
- Turn the eccentric (7) in such a ay that the required
clearance bet een the elements (1) and (2) is attained.
- Tighten duly the scre (6).
3
4
205o
57
6
1
2
5
5
295o
3
7
2
1
6
A
1
2
4
3
4
3.1.7 Setting the regulation of the hook lubrication
By turning the lubricating tube (1) in the sense of the arro
(2), the size of the contacting surface bet een the ick (3)
and the felt insert (4) is regulated. In this ay, the speed of the
capillary lift of oil into the felt insert (5) is influenced, from
hich oil is iped on the surface (6) and is driven by centrifugal
force into the hook path (7).
Setting of full lubrication
- Turn the scre (8) into the position (9).
Setting of limited lubrication
- Turn the scre (8) into the position (10).
After having ended the regulation, set the height of the
lubricating
tube (1) at 0.4 mm from the eccentric (11).
3.1.8 Replacement of the hook
Caution! Danger of injur !
S itch off the main s itch ! Before starting the
setting operation, eit until the motor stops!
- Remove the throat plate and the trimming knife.
- Unscre the scre s (1) and remove the gib (2).
- After having suitably turned a bit the hook, remove the
bobbin case (3).
- Unscre thorougly the scre (4).
- Remove the body of the hook (5) up ards.
- When mounting, the procedure is inverse.
3.1.9 Setting the gear
The mutual angular orientation of the gear heel (1) relative
to the gear heel (2) should ensure the accessibility of the
scre (5) at the moment hen the hook point comes to lie
opposite the needle (4). The heel (2) is to be set ith its gear
rim symmetrically to the centre of the gear heel (1). The
clearance bet een the gear heels is to be the least possible.
Caution ! Danger of injur !
S itch off the main s itch! Before starting the
setting operation, ait until the motor stops!
- Set the angle of 2O5° on the hand heel (6) and lock it ith
the scre (7).
- Remove box of the hook (8), according to the paragraph
3.1.10, the hook point (3) is to be turned a bit according to
the illustration.
- Turn the gear heel (2) into the suitable position and insert
the box of the hook into the machine. Check up, hether
the scre (5) is accessible and, if not, repeat the procedure.
- Set the the distance of the hook from the needle according
to the paragraph 3.1.3.
- Set the precise angular displacement of the hook according
to the paragraph 3.1.4.
- The scre s (10) tighten slightly.
- Set the clearence in the gear in turning the scre s (9). Check
up, hether the gear has a clearance during the hole
revolution of the hook. Turn the hand heel step by step by
15° and, ith each step, grasp the hook and try, if there is an
angular dead travel. Tighten carefully the scre s (9).
- Tighten duly the scre s (10) and try ane the clearance of
the gear.
1
2
3
7
6
205o
1
3
2
5
46
7
89
10
1
11
15o
4
5
51
23
4
8
910
9
10
0,4
5
3.1.10 Dismantling of the hook box
When dismantling the box (1), the supplies of lubricating oil
are to be disconnected first, the fastening scre s unscre ed
and, thereafter, the box is removed.
Caution ! Danger of injur !
S itch off the main s itch! Before starting the
setting operation, ait until the motor stops!
- Unscre the scre s (8) from the oil tank (4) and pull the
box out from the bedplate (7).
- Disconnect the lubricating tubes ith the icks (2) and (3)
from the oil tank (4).
- Loosen only one scre (5).
- Unscre the scre s (6).
- Shift the hook box in the sense of the arro and remove it
out from the machine.
- When mounting it, proceed inversely.
3.2 Needle and thread mechanism
3.2.1 Description
The take-up lever (1) is mounted in ball bearings, both at the
spot of its suspending on the connecting rod (2) and in the
mounting on the loop (12). The take-up lever is of aluminum
and is provided ith a stuck-in eye for t o threads. The
connecting rod (2) is mounted on the eccentric pin (3), by
means of hich the thread mechanism is adjusted according
to the category of stitching. The needle rod holder (4) is
mounted through the pivot (5) in a rotating ay in the arm (6).
In its top part, the holder is guided by the guide pin (7). The
movement for the needle feed is given to it by the connecting
rod (8) driven by the feeding shaft (9). The connecting rod (8)
is mounted by pin (13) ith needle bar holder (4).
The connecting rod (10) of the needle bar (11) on the loop
(12) is mounted in a ball bearing and it is slidingly mounted
on the needle bar carrier. The mechanism is lubricated by means
of a central- ick lubricating system.
3.2.2 To check the handwheel angular adjustment
The hand heel (5) must be situated in its precise position
relative to the needle and thread mechanism. This position is
given by a pin (2), hich locks the connecting rod of the
needle rod (1) through a hole in the arm (3). In this position,
the indicator (6) of the hand heel must sho O. The position
is fixed by the hand heel scre (4) contacting a small flat
surface provided on the upper shaft.
The correct adjustment of the angular position has been car-
ried out at the producers.
Caution ! Danger of injur !
S itch off the main s itch! Before starting the
setting operation, ait until the motor stops!
3.2.3 Height setting of the needle bar
At the moment, hen the hook point passes around the needle,
the upper edge of the needle eye must be about 1 mm belo
the hook point. In an opposite case, it is necessary to set the
height of the needle bar as follo s:
Caution ! Danger of injur !
S itch off the main s itch! Before starting the
setting operation, ait until the motor stops!
- Remove the front guard.
- Loosen the scre (1) of the needle bar carrier
- Set the correct height of the needle bar and tighten ane
the scre (1).
Caution !
An incorrect setting of the needle bar height may
cause the striking of the hook point against the
needle.
6
7
5
5
6
23
4
1
8
2
1
12
3
4
56
7
8
9
13
10
11
1
2
34
5
6
1
1
0o
6
3.2.4 Angular setting the pin of the thread
mechanism
The hinged pin (2) of the connecting rod (3) can be set in two
positions:
-for stitching category 100, 200, 300 - the groove of the pin
(2) is in position (t rned) as shown in Fig. A
- for stitching category 400 - the groove of the pin (2) is in
position (t rned) as shown in Fig. B.
Set the connecting rod pin as follows:
Caution! Danger of injury!
Switch off the main switch! Before starting the
setting operation, wait ntil the motor stops!
- Remove the front g ard.
- Loosen the screw /imb s/ (1) of the connecting rod (3) pin
(2).
- Set the pin into the corresponding position and tighten
anew the screw.
- The correct position is given by the flat on the pin (2), on
which the screw (1) is tightened.
-After having tightened the screw (1) check the axial
clearance of the connecting rod (3).
3.2.5 Side setting of the needle ar holder
In the correct position of the needle bar holder, the distance
A between the needle axis on the left side and the axis of the
apert re in the throat plate is 0,1 mm.
Caution! Danger of injury!
Switch off the main switch! Before starting the
setting operation, wait ntil the motor stops!
- Loosen the screw (1) of the pin (2).
- Loosen the screw (3) of the g ide pin (4).
- In shifting the pin (2) set the needle bar holder on the
meas re A = 0.1 mm /at the same time the pin (4) shifts.
- The g ide pin (4) is to be set in s ch a way that the needle
bar holder moves easily.
- Tighten the screws (1 and 3).
3.2.6 Setting the needle (the needle ar holder)
in the direction of sewing
When shifting o t the needle from the throat plate insert,
at the moment, when the needle eye is at the level of the top
s rface of the throat plate insert, the distance between
the needle and the wall of the throat plate insert m st be A =
0.2 mm.
Caution ! Danger of injury!
Switch off the main switch! Before starting the
setting operation, wait ntil the motor stops!
- Shift the insert (3) p to the stop in the sense of the arrow.
- Set the maxim m allowed stitch length.
- Set the handwheel (1) to the angle of 244°and lock it with
the screw (2).
-Loosen the screw (4) of the lever (5).
- By t rning the needle bar holder (6) on the pin (7) set the
req ired distance A = 0,2 mm.
- Tighten p the screw (4) and check p the setting.
Caution!
A fa lty setting may ca se bending or breaking of
needles against the throat plate insert.
A
1
2
244o
1
2
A
3
45o
1
2
B
3
44 stupnì
45o
3
4
2
5
A
1
4
5
6
7
A
7
3.3 Throat plate
3.3.1 Description
The throat plate (1) is universal for all categories of se ing. In
the throat plate there is mounted an exchangeable insert (2).
The machine is supplied ith several types of inserts differing
in the idth of their needle aperture (3), see tab. in the par.
11.2).
For ensuring a good function of the thread trimming device,
the insert can be set in various positions in the sense of arro s
in such a ay that the rear edge of the hole in the throat plate
(4) prevents unthreading the thread from the se n material
hen forming the first stitches at the beginning of the seam.
3.3.2 Mounting and removing the throat plate
and its insert
When mounting the throat plate (1), the finger (2) must engage
into the recess (3). To remove the throat plate insert (4), scre
out the scre (5), take out the asher (7), loosen the scre
(8), and remove the inlay (4) by oblique up ard movement
sho n by the arro .
Caution! Danger of injur !
S itch off the main s itch! Before starting the
setting operation, ait until the motor stops!
- Turn the finger (2) in the sense to ards the throat plate (1).
- Mount the throat plate (1).
- Scre in the scre s (6).
- Slide in the insert under the asher (9) in the oblique rear-
ard sense (4).
- Mount the insert (7) and scre in the scre (5).
- Tighten the scre (8).
- When removing the insert, proceed in an inverse sequence.
3.3.3 Setting the throat plate and its insert
The insert of the throat plate should be set in the machines
ith the trimming device in such a ay that the edge (1) is at
the distance A = 1 to 2 mm before the spot of interlacing of
the threads (2). For the stitches up to the length of 2/3 of the
maximum length, the insert is to be set in its extreme front
position in the sense of the arro . For long stitches, it should
be in its extreme rear position, against the sense of the arro .
With the machines ithout the trimming device, the insert is
in its extreme rear position.
Caution! Danger of injur !
S itch off the main s itch! Before starting the
setting operation, ait until the motor stops!
- Loosen the scre s (3).
- By applying a heavy pressure of the scre driver, shift the
insert in its required position.
- Tighten the scre s (3).
2
24
8
1
6
23
4
5
7
312
A
1
3
9
3