Duerkopp Adler 1180i-5 Troubleshooting guide

Instructions for service
1180i - 5
Minerva Boskovice, a.s., Sokolská 60, CZ - 680 17 Boskovice
Tel.: [phone], 453433, 494111 Fax: [phone] 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

8
3.4 Thread tensioners and limiter
3.4.1 Description
The main tensioners (1) serves for creating the tension of the
thread hen tightening the stitch. The auxiliary tensioner (2)
reduces the risk of pulling out of the thread after the thread
trimming hen removing the se n material, hen the thread
is passed through this material and hen the main tensioner
is relieved. The main tensioner is relieved by the mechanism
controlled by the shaft of the presser bar lifting (3) holding
the lever (4) ith a pulley. The motion is then transmitted by
the lever (5) and the tie rod (6) on the thread tensioner plate
(7) hose displacement (motion) relieves thethread tensioner
springs (8). In machines provided ith a thread trimming
device, the main tensioners (1) are relieved as ell upon the
s itching on of the electromagnet (10) hose electromagnetic
field ill attract the thread tensioner plate (7). The mechanism
of the adapting spring (12) maintains the upper thread in its
tensioned state hen passing through the hook and hen
entering the needle into the se n material. The thread limiter
(13) limits the length of the thread fed by the take-up lever
hen moving from the upper to the bottom dead centre to get
a controlled passing of the thread through the hook. The
auxiliary guide (14) maintains the upper thread in front of the
needle in a tensioned condition and helps against pulling the
thread from the needle after thread trimming.
3.4.2 Setting the tension of the main and auxiliar
tensioners
The tension of the main thread tensioners is regulated by
means of the nuts (1). The force of tensioning the thread is
measured by the dynamometer (2) as it is sho n on the
illustration. The size of this force differs according to the
category, and its orientation value is indicated in the par. 11.2.
The tension of the auxiliary tensioner is regulated using the
nut (3). It should be the least possible, but sufficient for
unthreading the thread from the se n material hen removing
the se n material from the pressing element ithout leaving
the tensioner.
3.4.3 Setting the tensioning mechanisms
of the main tensioners
In the rest position of the tensioners, hen pushing the plate
of the tensioners on the spot A 3.4.1, this plate must have
the socalled dead travel of about 0,5 mm. At this lifting, the
tension discs of the tensioners must not be relieved. This can
be attained by a suitable shaping of the relieving disc of the
tensioners - this has been set up in the manufacturing factory.
In the maximum opened position of the tensioners, the plate
of the tensioners, hen pushing it at the spot A 3.4.1, must
still have the minimum lifting. This can be attained hen axially
shifting the lever (3) ith the roller (5) on the shaft (4).
The disengagement of the main tensioners must be
coordinated ith the top roller lift. To achieve this, turn the
lever (3) ith the roller (5) on the shaft (4). The movement of
the roller (5) on the slanting surface (6) of the lever (7)
disengages the tensioners. In this ay, also alag of the upper
thread tension disengagement after the top roller lift can be
obtained.
Caution ! Danger of injur !
S itch off the main s itch! Before starting the
setting operation, ait until the motor stops!
-Remove the rear cover ith the top roller lift magnet.
- Loosen the scre s (1) and (2) of the lever (3).
3
4
5
610
A
7
2
1
13
12
14
8
2
3
1
4 1 7
3 2 5
8
0,1
6
9

9
- In the rest state of the machine ( ith not relieved tensioner
discs) set the lever (3) in turning it slightly on theshaft (4)
to a position in hich the roller (5) of the lever (3) is in
contact ith theslanting surface (6) of the lever (7) and is
about 0.1 mm distant from the flat surface (8) of thelever.
- At the maximum lift of the top roller, the roller (5) moves on
the flat surface (9) of the lever (7); in this condition, there
must be a minimal play at the tensioner plate lift ( hen
pushing qat the spot A (3.4.1), the plate must still have a
minimum lifting - bet een the roller (5) and the surface (9)
there is a minimum clearance). Retighten the scre s (1) and
(2), check the play, and correct it in case of need.
3.4.4 Setting the adapting spring
The mechanism of the adapting spring is in the machine arm
set by the pin (1) and fixed by the scre (2). The axial
adjustment shall ensure that the surfaces of the parts (3) and
(4) are aligned (the threaded thread must in no place break on
edges). The initial position of the adapting spring (5) shall
ensure that B = 1 to 1.5 mm (see the Figure).
Caution! Danger of injur !
S itch off the main s itch! Before starting the
setting operation, ait until the motor stops!
-Loosen the scre (2) and take the mechanism out of the
machine arm.
- Turning the body (6) relative to the pin (1), set the required
initial position of the adapting spring /the scre (7) has
been set at the producer´s so as to permit the turning
movement of the body (6) the scre must not be fully
tightened/.
- During the installation of the mechanism into the machine
arm take care of the axial adjustment of the mechanism.
- Retighten the scre (2) and check the adjustment.
- Loosen the nut (8) of the mechanism, insert a scre driver
into the notch of the scre (9) and set the required value of
the adapting spring. By turning the scre clock ise you
increase the spring force, and vice versa.
- Retighten the nut (8) and check the function of the adapting
spring.
3.4.5 Setting the thread limiter
The thread limiter is to be set in such a ay that, hen se ing
and passing the thread through the most distant point of the
hook, the spring (2) shifts by about 1/4 to 1/2 length of its
total length. This means that the thicker ill be the se n
material and the longer ill be the stitch length, the more ill
be the limiter shifted in the sense of the arro and inversely.
Under standard se ing conditions, the thread limiter is set in
its tested positions depending on the se ing category in
accordance ith the chapter 11.
Caution! Danger of injur !
S itch off the main s itch! Before starting the
setting operation, ait until the motor stops!
- Tighten the scre (3).
-Set the thread limiter (1) so as to ensure a minimum motion
of the adapting spring (2) hen the thread passes around
the bottom of the hook.
- Tighten the scre (3).
8
3
4
2
3
1
5
A
4
9
3
6
7
1
2
8
9

10
3.5 Feeding mechanism of the needle feed
and of the lower feed wheel
3.5.1 Description
The feeding mechanism is formed by the leverage (1) hich is driven
from the main shaft through the eccentric ith connection rod (2). The
feeding motion is transmitted by the shaft (3) on the clutch of the
bottom feed (7). The engaging and the disengaging function of the
clutch (7) is controlled from the lo er shaft (8) through the eccentric
ith the connecting rod (9) and through the edge coupling (10).
The feeding movement is transmitted by the shaft (11) through the gear
transmission (12) onto the heel feeder (13).
The stitch length is set by the knob (14) through the leverage (15) to
the feeding mechanism (1).
3.5.2 Stitch length mechanism
3.5.2.1 Setting the upper eccentric
The eccentric (1) must be set in its angular position in such a ay that
the horizontal component of the needle motion is in a phase delay from
the vertical component of this movement. This refers to the angle of
90° on the hand heel (2), hen the setting stick (3) is engaged into
the eccentric (1) and leans from above against the feeding shaft (4).
Caution! Danger of injur !
S itch off the main s itch! Before starting the setting
operation, ait until the motor stops!
-Set the angle 90° on the hand heel (2) and fix it ith the scre (5)
hich is component part of the accessory of the machine (tighten it
ith care).
- Loosen the gripping joints of the levers (6) and (7).
- Turn the feeding shaft (4) in such a ay, so that the recesses (flats)
point to ards the bedplate (o ing to the unambi-guous setting of
the eccentric by means of the setting bar).
- Insert the setting bar (3) into the hole in the eccentric (1) and prop
it from above against the feeding shaft (4).
- Shift axially the eccentric (1) on the shaft into its extreme positions
and place it in the middle.
- Tighten the scre s of the eccentric (1) to the maximum (one scre
first and, after having turned slightly the hand- heel, the second
scre as ell).
- Turn the feeding shaft (4) back into the position for setting the
leverage in such a ay, so that the levers (10) of the mechanism pass
in the spots of the recesses.
- Tighten the gripping joints of the levers (6) and (7).
- Test the sufficient clearance in the recesses of the feeding shaft (4)
and, using the levers (10) ith the maximum stitch length for ard
and rear ard  push against the reverse stitching lever.
- Correct eventually the position of the feeding shaft.
3.5.2.2 Setting the prop
In this machine ith a heel feed, the prop (1) is mounted in the pits
(A and C) as per the dra ing.
3.5.2.3aForward and rearward stitch length
distribution (rough)
The cam (1) is to be set at the respective angle in such a ay that the
stirrup (6) is oriented in such a position, so that the connecting rods (7
and 8) are in a line ith a thoroughly scre ed in knob (9) and ith
turning the hand heel at 0°. This setting can be done only after having
set the top eccentric according to the paragraph 3.5.2.1.
Caution! Danger of injur !
S itch off the main s itch! Before starting the setting
operation, ait until the motor stops!
- Set the zero stitch /scre in the knob (9) to the bottom of the cam
(1)/.
- Set the angle 0° on the hand heel and lock it ith the scre (4).
- Turn the scre (3) in the respective sense in such a ay that the
connecting rods (7 and 8) are in a line and tighten the scre (2).
4
31
13
12 7
8
11
9
10
5
614
15
2
C
D
A
B
1
4
0o
678
19
3
2
5
2
90o
6
10 1
4
3
7

11
3.5.2.3bForward and rearward stitch length
distribution (fine)
When setting the maximum length of the stitch, the for ard
and the rear ard stitch length must be equal ith the
maximum error of ± 5 %. This setting can be done only after
having set the needle bar holder in the direction of se ing
(par. 3.2.6) and the heel feed (par. 3.5.3.1.2).
Caution! Danger of injur !
s itch off the main s itch! Before starting the
setting operation, ait until the motor stops!
- Set the maximum stitch length .
- Place a suitable material under the presser foot and mark
therein the for ard and the rear ard stitch length.
- With an unequal length of the stitch, proceed to the
correction of setting by turning the scre s (2 and 3). When
tightening the scre (3), the for ard length of the stitch is
shortened and inversely. When tightening the scre (2), the
for ard stitch length is lenghtened.
-Each time first loosen one scre and then retighten the
other one.
3.5.2.4 Setting the control knob
(including the stitch length limitation)
The control knob (1) is to be set up in such a ay that, hen
turning it in counterclock ise sense up to the stop, the
maximum stitch length valid for the given se ing category is
attained (cat. 1: 3 mm, cat 2: 5 mm, cat. 3 and 4: 7 mm). The
scale of the control knob is to be oriented in such a position,
so that the scale end corresponds to the maximum stitch
length, excepting the first se ing category, here the stitch
length of the indicator is 3 mm.
Caution! Danger of injur
S itch off the main s itch! Before starting the
setting operation, ait until the motor stops!
- Scre in the scre of the control knob in such a ay, that
the spherical surface of the scre (3) bears on the seat of
the cam (4).
- Loosen the scre (5) and turn the control knob in the
clock ise direction, until the pin (6) of the knob (1) bears
on the pin (7). Tighten firmly the scre s (5).
- Turn the knob in the counterclock ise direction up to the
stop, hen the pin (6) of the knob (1) bears on the pin (7).
- In a se ing test check up the length of the stitch, if this
corresponds to the maximum stitch length valid for the given
se ing category.
- If the stitch is longer, loosen then the scre s (5) and turn
the knob in the clock ise direction and inversely. Tighten
firmly the scre s (5).
- Insert a scre driver into the hole (8) of the scale (2) and
adjust the scale in such a ay that the maximum length on
the scale is against the marking of the stitch length on the
machine arm.
- For the se ing category 1, set the control knob (1) on the
stitch length of 3 mm and check it by a se ing test.
- Loosen the scre s (5) and turn the control knob (1) in the
counterclock ise direction, until the pin (6) of the knob (1)
bears on the pin (7). Tighten firmly the scre s (5).
- Put a scre driver into the hole (8) of the scale (2) and adjust
the scale in such a ay that the value of the stitch length on
the scale against the marking on the arm is 3 mm.
3
2
1
2
5
3
4
6
7
5
1
28

12
3.5.3 Lower feed wheel
3.5.3.1 Feeding clutches
3.5.3.1.1 Description
The feeding clutch is formed by the clutch cover (1) driven
from the connecting bar (2), by the clutch star (4) driven from
the connecting rod (3) and by the carrier plate (5) firmly
connected ith the shaft (6). Of the clutch give the connecting
rods (2 and 3) an opposite direction s inging movement. The
clutch is coupled by means of the edge (7) on the connecting
rod (8) through the eccentric (9) hich is placed on the lo er
shaft (10).
In the position, hen the edge is disengaged, the star (4)
is shifted out from the frictioning engagement ith the lining
of the carrier plate (5) by means of the spring asher (11). The
plate (5) lining is then pushed by means of a flat profiled
spring (12) against the cover of the clutch (1).
In the position, hen the edge is disengaged, the star (4)
is pushed against the plate (5) lining and, at the same time,
the friction connection ith the cover of the clutch (1) is
disconnected. Within a short instant, hen engaging and
disengaging ith the carrier plate (5), there are in a friction
engagement both the cover (1) and also the star (4), namely in
the dead centre of the connecting rods (2 and 3). The setting
of the change-over of clutches is done by tightening or by
loosening the nut (13).
3.5.3.1.2 Setting the lever of the second step of
feeding (angle, position)
The lever of the second step (1) must be set in such a ay
that, in the bottom dead centre of the needle, the axis of the
spider part (2) lies in the scre axis (3). The pin scre (4) can
be mounted into the position (4.1 - corresponds to the
maximum stitch length of 5 mm) or into the position (4.2 -
corresponds to the stitch length of 7 mm). The position of the
pin scre is given by the se ing category (see par. 11.2).
Caution! Danger of injur !
S itch off the main s itch! Before starting the
setting operation, ait until the motor stops!
Lever (1) displacement.
- Loosen the scre (6).
- Set the maximum stitch length.
- Set the angle 180° on the hand heel.
- Unscre the scre (5) and put the needle shank in its hole.
- Turn the lever (1) until the needle drops into the clutch disk (2).
- Side set the lever (1) to the measure A= 0.5 to 1 mm.
- Tighten the scre (6).
- Scre in the scre (5) and seal it ith the Loctite cement.
Change of the position of the pin scre (4).
- Remove the retaining ring (7).
- Unscre the scre (4) and scre it into the ne position
and tighten it duly. Mount the connecting rod (8) and the
retaining ring (7).
3
9
1
13
7
412
5
11
6
10
8
2
2
5
78 14
A
6
8
2
4.2
1
4
4.1
3
5

13
3.5.3.1.3 Setting of the lower eccentric
The rotation of the eccentric (3) must be delayed in phase by
1/4 revolution against the rotation of the eccentric of the stitch
length. This corresponds to the angle of 244° on the hand heel
(1), hen the setting pin (4) is put into the eccentric (3) hich
is in contact ith the indented belt (5).
Caution! Danger of injur !
S itch off the main s itch! Before starting the
setting operation, ait until the motor stops!
- Set 244° on the hand heel (1) and lock it ith the scre
(2), hich is included in the accessory of the machine
(tighten it carefully).
- Put the setting stick (4) into the hole in the eccentric (3) and
prop it from belo against the indented belt (5).
- Set eccentric (3) axially.
- Tighten it the utmost the scre s of the eccentric (6).
- By means of the hand heel, turn the eccentric (3) into the
marked position and check in this position the clearance
A = 0.05, proceed eventually to its correction by a ne
side setting of the eccentric.
3.5.3.1.4 Setting the engagement and
disengagement of the clutches
The nut (7) is to be side set in such a ay that the shifting of
the clutches is done at the moment hen the clutch disks (3)
do not move, hich means, hen they are at the dead center
of their oscillating movement. This corresponds to the angle
90° on the hand heel.
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 of the indented pulley of feeding and
shift it to the left.
- Set the maximum stitch length.
- Set the angle 90° on the hand heel (1) and lock it ith the
scre (2). hich is included in the accessory of the machine
(tighten it carefully).
- Loosen three scre s (6) in the nut (7) and unscre it by
2 mm to the left.
- Tighten slo ly the nut (7), until it strikes against the axial
bearing (9). (At this moment, the tightening moment
increases in jumps) and tighten the scre s (6).
- Set the the hand heel on 85° and push the backtacking
lever, the feeder is to turn against the movement of the
needle. Set then the hand heel on 95°, the feeder is to be
turned in the sense of the needle movement. If not being
so, correct the side setting of the nut (7). When the clutches
shift too soon, turn a bit the nut (7) to the right and inversely.
- Tighten the scre s (6).
- Return the indented pulley in its original place according to
the paragraph 3.6.2.
1
2
90o
3
6
45
A
244o
2
1
6
793

14
3.5.3.2 Wheel feeder and its post
3.5.3.2.1 Height setting of the feeder
The heel feeder (1) is to be set in such a ay that the points
of its teeth overtop the throat plate insert by X= 0.3 to
0.7 mm. When se ing soft and thick materials, it is necessary
to increase the value X, until a good quality of feeding is
attained, but only to the measure of not deteriorating the
beginning of se ing after the carried out thread trimming. Set
the height of the feed dog using a setting gauge as per the
respective figure.
Caution! Dangere of injur !
S itch off the main s itch! Before starting the
setting operation, ait until the motor stops!
- To increase the tooth height above the throat plate, scre in
the scre (2) by the required value.
- To reduce the height, proceed inversely.
3.5.3.2.2 Replacement of the feeder
For the replacement of the heel feeder according to the
machine setting - see par. 11.2 - setting of the machine - feeder
- pitch of the teeth.
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 (1) and remove the throat plate (2).
- Unscre the scre (3) and pull out the feeder (4) ith the
guide (5).
- Replace the feeder (4).
- Insert the feeder ith the guide into the groove and scre
the scre (3) in.
- Mount the throat plate (2) and tighten up the scre s (1).
3.5.4 Setting the top roller (pressing force, height)
When lo ering the top roller (1), set the clearance A bet een
the feeder (5) and the top roller to the maximum of 0.2 mm.
Set the pressing force of the top roller (1) so as to avoid the
slippage of the se n material hen feeding it.
Method of setting the height of the top roller:
- Lo er by hand the presser bar (3) ith the top roller (1)
above the heel feeder (5).
- Loosen the scre (4) and set the required value A (0.2
mm).
- Tighten the scre (4).
Setting the force of the top roller (1).
- In scre ing in the scre (2),the force of the top roller is
increased and inversely.
2
X
4
13
2
5
1
2
1
4
3
5A

15
3.6Feeding mechanism of the top roller
3.6.1 Description
The starting movement for the drive of the top roller feeder is
the bottom feeding shaft. From this shaft, the movement is
transmitted by the indented belt (1) onto the top feeding shaft
(2). A component part of the transmission by indented belt is
the pulley ( ), the tensioning roller (4), the roller (5) and the
pulley (6). Starting from the shaft (2), the movement is further
transmitted through the wheels (7 and 8) ontothe articulated
shaft (9). From this articulated shaft, the movement is
transmitted by a cone transmission, situated in the holder
(10), onto the feeder wheel (11). The shaft of the wheel (8) is
mounted in the screw (12) on bearings. The articulated shaft
(9) contains two joints (15) and a telescopic part (16). Both
these elements secure the lifting and the tilting of the top
roller.
3.6.2 Side setting of the indented lower pulley
The pulley must be set up in such a way that the belt passes
through the centre of the passing hole in the bedplate. The
setting operation is to be done as follows:
Caution! Danger of injury!
Switch off the main switch! Before starting the
setting operation, wait until the motor stops!
- Loosen the screws (1) of the pulley (2).
- Loosen the screw ( ) of the tensioning roller (4)
- Set the pulley (2) in such a way that the belt (5) passes
through the centre of the passing hole in the bedplate (6).
- Tighten the screws (1).
- Set the tensioning roller (4) axially in such a way that the
belt (5) is set at the middle of the tensioning roller (4).
- Set the tensioning roller (see par. .6.4).
- Tighten up the screw ( ) of the tensioning roller (4).
3.6.3Side setting of the indented upper pulley
The pulley is to be set in such a way that the indented belt is
not crossed and the pulleys are in line. The setting thereof is
to be done as follows:
Caution! Danger of injury!
Switch off the main switch! Before starting the
setting operation, wait until the motor stops!
- Loosen the screws (1) of the pulley (2).
- Set the pulley (2) in such a way that the distance of 5 mm
is attained in accordance with the illustration.
- Tighten the screws (1).
"
!
#

$
$
#

"
!
#
'
$
#


&! "
%

#

16
3.6.4 Setting the tensioning roller
The tensioning roller of the indented belt of the top feeding
is mounted in a rotary way on the bedplate. The belt must be
ten-sioned as needed in such a way that there is ensured the
correct function of the transmission. Insufficient tension can
cause skipping of the teeth, on the contrary, excessi e
tensioning enormously loads the mounting of the top shaft.
The setting thereof is to be done as follows:
Caution! Danger of injury!
Switch off the main switch! Before starting the
setting operation, wait until the motor stops!
- Loosen the screw (1) securing the le er of the tensioning
roller (2).
- Tension the belt as needed (theoretically, in applying the
force of 10 N in the middle of the belt with the deflection of
4 mm).
- Tighten the screw (1).
3.6.5 Replacement the indented elt
Before replacing the indented belt, the bottom feeding shaft
is to be remo ed. The procedure is as follows:
Caution! Danger of injury!
Switch off the main switch! Before starting the
setting operation, wait until the motor stops!
- Loosen the screw (1) of the tensioning roller (2) and loosen
it.
- Loosen the screws (3) of the pulley (4) and shift it to the left
in such a way that the screws (5 and 6) of the feeding clutch
(7) are accessible.
- Loosen the screws (5 and 6).
- Loosen the screws (8) of the axial ring (9).
- Loosen the screw (10) of the clutch (11).
- Push the shaft (12) to the right in such a way that it is out of
the pulley (4).
- Remo e the pulley (4).
- Remo e the front guard.
- Loosen and unscrew the screw (14) of the holder of the
wheel (15) and remo e it from the holder (21).
- Loosen the screws (16 and 17) of the holder (18).
- Remo e the holder (18) together with the holder (15) and
articulated shaft (13) from the machine.
- Loosen the screws (19) of the pulley (20).
-Loosen the screw (24) of the ring (25).
- Hold the pulley (20) and pull out the feeding shaft (22) from
the arm in such a way that it is possible to remo e the
indented belt (23) from the arm of the machine.
- Replace the belt with a new one and proceed to the assembly
(in erted procedure of dismantling).
- Proceed to the setting operation according to the par. 3.6.2,
3.6.3 and 3.6.4.
 "!& '

#$ %

#
"
"
#
!
%
&
$
!

'




17
3.6.6 Top roller
3.6.6.1 Selection of the top roller diameter
The machine can be supplied ith t o types of top roller,
namely ith the diameter of 25 mm and ith the diameter of
35 mm. The suitability of the diameter used depends on the
type of se ing and on the concrete technological operation.
There are in general valid the follo ing principles for the
selection of the heel diameter:
ø 25 mm - for se ing small radii
ø 35 mm - for se ing straight sections or big radii
- for se ing ith great passages to thicker materials
3.6.6.2 Forward, rearward and side setting
The top roller must be in a defined position in relation to the
needle:
a)vie (see Fig. 1) - the value X depends on the diameter of
use top roller (ø 25 - 6.5 mm; ø 35 - 10.5 mm), it is measured
from the the needle bar up to the roller edge hen turning
the hand heel to the 180° of the scale against the indicator
b)vie (see Fig. 2) - the heel edge must fit ith the edge of
the needle operture at the spot of the needle punch.
These values are to be set as follo s:
Caution! Danger of injur !
S itch off the main s itch! Before starting the
setting operation, ait until the motor stops!
- Loosen the scre (1).
- By shifting the holder (2) ith the top roller (3) in the groove
of the holder (4) set the required value X and tighten the
scre (1).
- Loosen the scre (5)
- By shifting the holder (2) in the holder (6) set the bottom
edge of the roller to the edge of the needle operture.
- Tighten the scre (5).
3.6.6.3 Setting the gear clearance
and in the mounting of the top roller
In the cone gear of the drive of the top roller foot, the minimum
clearance must be set. A too small clearance ill increase the
friction resistance of the gear, the excessive clearance ill
influence the inaccuracy of feeding. The top roller itself is
mounted on balls. With this type of mounting,it is also
necessary to set the minimal possible radial clearance.
The given clearances are set as follo s:
Caution! Danger of injur !
S itch off the main s itch! Before starting the
setting operation, ait until the motor stops!
Clearance in the wheel mounting
- Loosen three scre s (5) /only slightly/.
- Using the scre (4) set the minimum clearance in the top
roller mounting (2) /it must easily rotate ithout any rubbing
and ith a minimum clearance/.
- Tighten the scre s (5), check the set up clearance, even-
tually, repeat the setting procedure.
Clearance in the conic gear
- Loosen the scre (1), in shifting the heel, resp. the holder
(3) in the holder groove (6), set the minimum clearance,
the pinion (7) must be pushed up to the holder bottom (6).
- Tighten the scre (1), check the set up clearance.
4
3
1
2
7
5
6
X
3
2
6
5
1
4
Fig. 2Fig. 1