Minerva Boskovice 4182i-1 User manual

Instruction manual
4182i - 1
Minerva Boskovice, a.s., Sokolská 60, CZ - 680 17 Boskovice
Tel.: [phone], 453433, 494111 Fax: [phone] http://www.minerva-boskovice.com
Edition/Vydáno/Herausgegeben/Edition/Editado: 05/2009
Printed/Tisk/Druck/Imprimé/Impress ã o: Czech Republic S735 000688

Contents - part A - Instruction manual:
1. Proper use of the machine .................................................................................................................................................. 1
2. Description of the machine ................................................................................................................................................. 1
3. Machine sub-classes and sewing categories .................................................................................................................... 2
3.1 Sub-class .................................................................................................................................................................. 2
3.2 Sewing categories .................................................................................................................................................... 2
4. Survey of equipment ............................................................................................................................................................ 2
4.1 Equipment ................................................................................................................................................................. 2
4.1.1 Needles ........................................................................................................................................................... 2
4.1.2 Wheel feeders ................................................................................................................................................. 2
4.1.3 Top roller holders ........................................................................................................................................... 2
4.1.4 Top rollers ....................................................................................................................................................... 3
4.1.5 Throat plate .................................................................................................................................................... 3
4.1.6 Throat plate inserts ........................................................................................................................................ 3
4.1.7 Trimer knives .................................................................................................................................................. 3
4.1.8 Gauge for knife setting ................................................................................................................................... 3
4.1.9 Connecting cables of the head to the drive................................................................................ .................... 3
4.2 Optional eqiupment ................................................................................................................................................. 3
5. Technical data ..................................................................................................................................................................... 3
6. Operation of the machine .................................................................................................................................................... 5
6.1 Threading a thread ................................................................................................................................................... 5
6.2 Bobbin thread winding ............................................................................................................................................. 5
6.3 Inserting the bobbin and threading the lower thread ............................................................................................ 5
6.4 Regulating the thread tension ................................................................................................................................6
6.5 Needle replacement ................................................................................................................................................. 7
6.6 Regulation of pressing the top roller ...................................................................................................................... 7
6.7 Lifting the top roller up ............................................................................................................................................ 7
6.8 Reverse stitching...................................................................................................................................................... 8
6.9 Stitch length adjustment .......................................................................................................................................... 8
6.10 Safety clutch ............................................................................................................................................................. 8
6.11 Starting of the material trimming operation .......................................................................................................... 8
6.12 Control of the material guide regardless the engaged trimming ......................................................................... 9
6.13 Control of the material guide with regard to the engaged trimming device ........................................................ 9
6.14 Setting of the material guide .................................................................................................................................. 9
6.15 Replacement of the trimming knife ........................................................................................................................ 10
6.16 Setting of the trimming device for trimming very small radii ............................................................................... 10
6.17 Setting of the trimming device for trimming thin, soft materials ......................................................................... 10
6.18 Change of the sewing category ............................................................................................................................... 10
6.19 Sharpening of the knives ......................................................................................................................................... 10
7. Electronic control of the machine ...................................................................................................................................... 11
7.1 Control of sewing by means of control elements ................................................................................................... 11
7.1.1 Via treadle ....................................................................................................................................................... 11
7.1.2 Via control pushbutton panel......................................................................................................................... 11
7.1.3 Via control panel V810/V 820......................................................................................................................... 11
7.2 Adjustment of automatic functions via control panel for stop motor ................................................................... 12
7.2.1 By using stop motor Efka with panel V 810 ................................................................................. .................. 12
7.2.1.1 Adjustment by means of buttons with fixed setting function ........................................................... 12
7.2.1.2 Setting by means of parameters ......................................................................................................... 13
7.2.2 By using stop motor Efka with panel V 820 ................................................................................................... 14
7.2.2.1 Adjustment by means of buttons with fixed setting function ........................................................... 15
7.2.2.2 Setting by means of parameters ......................................................................................................... 15
8. Maintenance ........................................................................................................................................................................ 16
Operating instructions for eventual trouble shooting ....................................................................................................... 17

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 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 tread-ing, 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 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.
It is absolutely necessary to respect the safety instructions marked by these signs.
Danger of bodily injuries !
Please note also the general safety instructions.
IMPORTANT WARNING!
To the feeding network cord, it is necessary to connect the respective network plug which has been approved in the country
of utilizing the machine. This operation should be performed by a worker acquainted with the electric safety rules being in
force in the given country. The supplier is not responsible for any damages caused by defective plug or owing to incorrect
assembly of the plug.
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.
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.
3. 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 tread-ing 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.
5. Moving work cutter knife and work guide at the work cutter start
- injury danger at incidental finger insertion under the cutter knife.
6. Moving connecting rod of the work cutter at the work cutter start
- injury danger at incidental finger insertion between the connecting rod and the body of the work cutter.
7. Moving work cutter motor at the work cutter start
- injury danger at incidental finger insertion between the motor and the work cutter guard.

1
Part A - Instruction manual
1. Proper use of the machine
The machine is used in the shoemaking industry for sewing shoe uppers, for sewing on linings with simultaneous lining edge
trimming under the angle of 20° in the manufacture of shoe uppers. In addition to this, the machine serves for assembling
individual shoe parts, as well as for decorative stitching without edge trimming. The machine is suitable for other similar
operations in the fancy goods industry. The machine is able to sewing upper leathers, natural or synthetic leather, eventually in
combination with textile materials. Trimming is always to be done with a sharp knife. The knife is driven by a self-contained motor
and its rear edge is situated 6 mm behind the needle axis. It ensures a good quality trimming of the lining material both in inner
and outer curves. When trimming soft materials, the operator should maintain them, in pulling the trimmed lining behind the
needle, in a stretched condition to make the trimming operation easier.
The machine sews using a double-thread lock stitch. A combined feeding ensures a uniform feeding of all layers to be sewn
together. The machine has got a standard outfit with the 134 KKL needles suitable for sewing leather. For sewing textile materials,
the needle system 134 is being used. In general, only dry material may be sewn, which is not thicker than 6 mm after having been
compressed by the roller presser foot. The material should not contain any hard objects, for the machine is not provided with any
eye protector.
For sewing, textile threads up to the dimension 500 dtex x 1 x 3 (label No 20) are to be used, namely synthetic, cotton or core
spun threads. When needing other special threads, one must take into account the respective risks and proceed to the necessary
safety measures. When sewing very hard or consistent materials or when sewing with edge trimming, the sewing speed must be
considerably reduced below the values given in the technical parameters of the machine.
These special machines may be installed and operated only in dry rooms kept in orderly conditions. When operating them in
rooms which do not meet such conditions, there must be done some additional measures according to the EN 60204-31
standard. In our position of the manufacturers of industrial sewing machines, we start from the assumption that our products are
operated by an at least initiated operator, so that all usual operating activities and their eventual riks can be supposed to be
known.
Machine noisiness
Machine noisiness has been measured in accordance with the standards ISO 3746, ISO 11204 at maximum speed.
Laeq = equivalent machine noise of the self-standing machine on the working place, converted to % machine employment (dB)
- stated in the table
2. Description of the machine
This is a one-needle post-bed sewing machine with a standard vertical hook situated to the right from the needle. The feeding is
of a two-step type with a driven top roller presser foot and with a circular bottom feed combined with a needle feed during the first
step of the workpiece feeding. The main mechanisms are mounted on antifriction bearings, swing shafts and pins are slidingly
mounted. Feeding is derived from the mechanism of changing stitch length through a friction clutch on the bottom feeding shaft.
From here the circular feeder is driven by means of a roller chain. The drive of the roller presser foot is derived from the bottom
feeding shaft through an indented belt on the top feeding shaft through abevel gearing on an articulated vertical shaft. The
needle feeding is derived from the same mechanism as the circular feeding. The stitch length is set using a knob on the web of
the machine arm.
The machine is provided with a thread trimming device, with an electromagnetic roller presser foot lifting, with an electromagnetic
backward stitching. This backward stitching is controlled by a hand lever or by a microswitch in the event of having provided the
machine with an electromagnetic backward stitching. The machine has got a sewing set mounted with changeable needle plate
inserts according to the needle number and according to the distance of trimming from the needle. It i possible to choose the
roller presser foot of 25, 35 or 45 mm. The standard vertical hook has got its own forced bobbin case opening. The hook is
protected by a protective coupling against overload with an adjustable switch-off moment. There is a central pressureless wick
lubricating system. The hook is excluded from this system, it is lubricated separately with its own lubricating regulation. Each
machine has got a built-in hook thread friction winder mounted. The machine can be provided with a halogen lamp lighting,
eventually with further possible outfit. When the machine has no electromagnetic roller presser foot lifting, this lifting is controlled
by the knee lever or, in case of deliveries for the Czech Republic, by the left pedal.
The frame is fitted with a wedge. In accordance with the roller presser foot lifting outfit, the frame is fitted with one or two pedals.
For the edge trimming operation, the machine is provided with an oblique top trimming device. The knife is driven by a leverage
from a separate motor, which is situated on the machine arm. The knife is started by a lever and is automatically shifted into its
working position. With machines provided with the EFKA stop motor, the motor of the trimming device is being switched on only
at the beginning of the sewing operation and it is switched off with an adjustable delay after having ended the sewing operation.
By returning the lever back, the lever movement is stopped and the knife moves upwards, outside from the sewn workpiece.
Together with the machine there is supplied a tiltable material guide. Putting this guide in its working position is mechanically
selectable either separately from the trimming operation or together with the trimming.
Type of the Noisiness % machine
machine dB employment
4182i-XXX-100 82 20
4182i-XXX-200 79 20
4182i-XXX-300 73 20

2
3. Machine sub-classes and sewing categories
3.1 Sub-class
Table 1
*for only Czech republic
3.2 Sewing categories
This code indication includes the equipment assembled on the machine head, both necessary equipment and optional equip-
ment. The standard configuration of the equipment has been preset, according to the under mentioned table, in the factory which
includes only necessary equipment. If the buyer demands a different configuration then the factory allocates a new code
indication.
Table 2
Standard configuration - the numbers in brackets stand for ordering Nos. when ordering separately the Equipment in question
Type Needle size Top roller Wheel feeder Throat plate Throat plate
insert
Class-sub-class Diameter Pitch of teeth Width of hole
-sewing category 0.01mm mm mm mm -
4180i-1XX-100 80 35 0.4 1.2
(S548 134013) (M 173) (M 060) (M 191)
4180i-1XX-200 100 35 0.4 1.5 (M 091)
(S548 134001) (M 173) (M 060) (M 192)
4180i-1XX-300 130 35 0.6 2.0
(S548 000311) (M 173) (M 059) (M 193)
4. Survey of equipment
This survey does not include the equipment assembled on the stand.
4.1 Equipment (at least one of each from the following group of equipment is assembled)
4.1.1 Needles
M 020 - needle 134 LR size 80
M 023 - needle 134 LR size 100
M 021 - needle 134 LR size 130
4.1.2 Wheel feeders
M 060 - wheel feeder with pitch of teeth 0.4 mm
M 059 - wheel feeder with pitch of teeth 0.6 mm
M 058 - wheel feeder with pitch of teeth 1.2 mm
4.1.3 Top roller holders
M 156 - holder for the top roller ø 25 mm
M 157 - holder for the top roller ø 35 mm
M 295 - holder for the top roller ø 45 mm
••••
•
••
••
•
Type of Top roller lift Reverse stitching Thread
the machine trimmer
Class-subclass Via knee Treadle Via electro- Via electro- Via hand Via electro-
-sewing lever mag. + mag. + lever mag. +
category knee lever treadle hand lever
4182i-111-XXX
4182i-121-XXX*
4182i-147-XXX
4182i-157-XXX*
.

3
4.1.4 Top rollers
M 172 - top roller ø 25 mm
M 173 - top roller ø 35 mm
M 174 - rubberized top roller ø 25 mm
M 175 - rubberized top roller ø35 mm
M 310 - smooth top roller ø 25 mm
M 311 - smooth top roller ø 35 mm
M 296 - top roller ø 45 mm - width 2.0 mm
M 297 - top roller ø 45 mm - width 3.8 mm
4.1.5 Sewing set
M 143 - sewing set
4.1.6 Throat plate inserts
M 191 - insert for throat plate (for needle 60-80; trimmed edge 0.8 mm)
M 192 - insert for throat plate (for needle 80-110; trimmed edge 1.2 mm)
M 193 - insert for throat plate (for needle 110-140; trimmed edge 1.5 mm)
M 320 - insert for throat plate (for needle 110-140; trimmed edge 2.4 mm)
M 321 - insert for throat plate (for needle 110-140; trimmed edge 3.0 mm)
M 323 - insert for throat plate (for needle 110-140; trimmed edge 2.0 mm)
4.1.7 Trimmer knives
S425 870237 - trimmer knife A (hard metal)
S080 870235 - trimmer knife A (steel)
S080 870238 - trimmer knife B (steel)
S080 870239 - trimmer knife C (steel)
4.1.8 Gauge for knife setting
M 268 - gauge
4.1.9 Connecting cables of the head to the drive
M 318 - connecting cable to the drive EFKA DC 1600/DA82GA; EFKA VD 552/6F82FA and EFKA VD 554/6F82FA
M 055 - connecting cable without any specified drive (with free cable end)
Note: For the machine provided with a minimotor, the cable is component part of the drive thereof.
4.2 Optional equipment
M 010 - built-in lighting (including transformer 230/12V)
M 269 - jig for knife sharpening
M 242 - setting gauge
4182 111001V - high mortality spare parts kit in plastic box for sub-class without thread trimmer
4182 147001V - high mortality spare parts kit in plastic box for sub-class with thread trimmer
S794 222012 - halogen lighting (12 V, 20 W - contains transformer)
5. Technical data
Table 3a
Sewing Distance Stitch Labelled Number Sewing speed Hook Throat Thickness Play be-
category between the length number of of needle (without trimming) plate of the top tween the
needle axis polyester thread insert material guide and
and the work the knife
trimmer line
mm mm - - 0,01mm 0,01mm SPM SPM - - mm mm
- 100 0,8 3 70 80-60 80 60-80 2500 3500 R 816 M191 0,8-1,2 0,2
- light
-200 1,2 5 40 50-30 100 80-110 2500 3000 R 816 M192 1,2-1,6 0,3
- medium
- 300 1,5 5 20 30-20 130 110-140 1600 2000 R 816 M193 1,6-2,4 0,4
- medium
-heavy
Standard
Maximum
Standard
Range
Standard
Range
Standard
Maximum
Range
Recommended

4
Table 3b
Recommended speed at simultaneous work trimming
To observe: To obtain uniform stitch length, the sewing speed must be reduced. The recommended values apply to current leathers
used in the shoe industry. For extremely soft or extremely hard leathers, tests should be carried out and the sewing speed should
be adjusted accordingly.
The recommended speed has been chosen so as to correspond to the assortment of the available pulleys.
Stitch type Double thread lock-stitch 301
Hook R 816 - standard, vertical
Needle System 134; 134LR; 134 KKLR
Threads max. 500 dtex x 1 x 3
Stitch length max. 5 mm ± 10%
Sewing speed max. 3500 SPM (the maximum sewing speed with the
simultaneous trimming is limited by the stitch length
and by the hardness of the material being trimmed)
Top roller stroke 5,5 ± 0,5 mm - via hand lever
12.5 ± 1 mm via electromagnet
Length of trimmed thread ends 8....11 mm
Height of post bed 173 mm
Opening space of machine head 270 x 298 mm
Weight of the head max. 55 kg (61 kg head with minimotor)
Weitght of the stand max. 60 kg (38 kg for head with minimotor)
Driving unit Clutch motor (min. 0.35 kW)
Stopmotor (min. 0.4 kW)
Dimension of bed plate 178 x 518 mm
Input machine max. 600 W
Trimmed material max. thickness - 2,5 mm
Distance between the needle axis and the work trimmer line 0,8 - 1,5 mm (according to sewing category)
Power output of the work trimmer motor 25 W
Stroke frequency of the work trimmer knife 3500 strokes/min (constant)
Stroke range of the work trimmer knife adjustable to 2,4 mm
Layout dimensions of the machine (including the stand) 1060 x 550 mm
Height of the machine (including the stand) 1680 mm
Stitch length Sewing speed
mm SPM
1,5 2500
2,5 2000
4 1200
5 800
S080 870235 S425 870237 S080 870238 S080 870239
Thickness of
the material trimmed
1 - 4 1,5 - 4 1 - 2 0,2 - 0,8
Minimum radius for the
material being trimmed
~6 ~6 ~4 ~6
Knife stroke
2,4 2,4 1,2 2,4
steel hard meal steel steel

5
6. Operation of the machine
6.1 Threading a thread
Caution! Risk of injury!
Before threading a thread, turn the main switch
off and wait until the machine stops!
Thread the threads as it is shown in picture.
Caution!
Not following the correct method of threading a
thread may cause serious damage to the function
of the machine.
6.2 Bobbin thread winding
- Insert the bobbin (1).
- Spool counter-clockwise manually onto the bobbin, mini-
mum six threads of the lower thread (3).
- Insert the thread ends into the equipment (4) and cut off the
ends.
- Press the lever (2) until it reaches its limit.
- Switch on the machine.
- The winder will automatically switch off after winding.
- Take off the hook bobbin and cut off the end in the equip-
ment (4).
- The nut (5) is instrumental to thread tension control for
winding. Turning clockwise sense the thread tension is in-
creased and the single threads are more firmly fixed on the
bobbin.
- The tension cannot be so extensive as far as slipping of the
winder friction drive has occured.
6.3 Inserting the bobbin and threading the lower
thread
Caution! Risk of injury!
Turn the main switch off and wait until the motor
stops!
- Tilt the shutter (1) up.
- Insert the bobbin (2) with thread end (3) in the direction as
shown in the picture.
- Thread the thread through the notch (4) and the space (5)
and place under the spring (6).
- Cut off the thread end as shown.
1
2
4
3
5
3
2
6
~ 10
5
4
1

6
6.4 Regulating the thread tension
The thread tension must conform to the thickness of the sewn
threads, thickness and hardness of sewn material (thin and
soft material will fold with high tension) and the kind of seam.
An ordinary fitting seam should be formed with stitches knit-
ted in the middle of the sewn material.
A decorative seam is mostly used with rough threads (20) on
thin material and it has tied up threads on the reverse side of
the material for achieving a decorative appearance.
Thread tension adjustment is by standard sewing (par. 5, ta-
ble 3) conditions in accordance with table No. 4.
If achieving of a decorative seam with stitch knitting on the
underside is wished, it is necessary to decrease the upper
thread tension, it is carried out by turning of nuts (1), in the
counter-clockwise sense.
Thread tension
Table 4
Sewing Kind of seam Identified Maximum
category value upper tension of
thread tension lower thread
NN
1- 31
2 - 4.5 1.5
3Fitting 8 2
Decorative 5
If the maximum lower thread tension exceeds the
values given in table No. 4, it may cause problems
in the beginning of sewing after the previous
thread trim.
Measurement of tension is done by dynamometer.
Warning:
The upper thread tensioner has been loosened automatically
after every trimming and top roller lifting. In these cases the
thread tension cannot be measured.
Regulating the thread tension
Caution! Risk of injury!
Before regulating the lower thread tension, turn
the main switch off and wait until the motor stops.
The upper thread tension is adjusted with nuts (1). Its clock-
wise turning increases the tension.
The tension of the auxiliary tensioner (3) should be as low as
possible but it should be on a level so that the upper thread
would not pull out of the tensioner when the work is being
removed.
The lower thread tension is adjusted with a screw (2). Its clock-
wise turning increases the tension.
Tension correlation rate defines the depth of the seam tied
through. The result of raising the upper tension will be the
decreasing depth of tie through. The opposite will apply with
the lower thread.
1
3
2
Fitting seam
Decorative seam
Stitch knitting
Stitch knitting