Contents: Part 3: Service manual 1. Sowing machine (cl 805-121) 11 Hook, needle bar and nesele guide 1.2. Bobbin case opener 13. Sewing foot 1.4 Cheek spring 1.8 Thread tension cslease 18 Oillubeeaton 17am postion 2. Sewing machine el. 805-111) 2.4 Sitch regulator and conneetion lever 2.2 Rooker anc toe plat 2.3 Hook, noes ba, hook guard and needle guide 24 Bobbin case opener 25 Sowing foot 2.8 Check spring 27 Thread tension release 28 Thread puller 29. Satetyciuteh 2.10 Oil hoieaton 2.11 Sewing arm 2.12 Turning cylinder ‘or the hook box ‘Thread trimmer (cl. 805-121) ‘Thread trimmer (el 805-111) 5. Folding device 51 Outer frame 5.2 Inner trame 53 Contra sider 154 Sido, front and comer sir 5.6. Setting ofthe tw cals 6. Transter carriages: 6.1 General infermaton 8.2 Transtor distance he carriages 1.3 Equalization of psitin o the cartages tothe folding and sewing station 8.4 Position ofthe carriage with respect to the miling sation 8.5 Zero pont poston of the carriages 5.6 Activation timing ofthe lit switches 187 Poston ofthe step pin... + 18 1416 4749 20,21 2 2 2 24.28 28 29.90 490 39,40 4“ 4244 4547 “ 4055 se-61 62,69 6 6Contents ™ 7a 78 a 73 79 a a4 82 33. rv 85 ay 92 93 rv os. 96 a7 98 29 10. ‘stacker ‘General information Function sequence ofthe stacker Lateral poston of the ejector and stacker Low and high speed of the lector rolor Pesition of tho open inner bracket Postion ofthe open outer bracket Sensitivity ofthe light barter Lower postion ofthe ajactrrlie Speed of ho outer bracket, nner bracket and support ‘Speed “Elector rollers up or down" ‘ijt intensity and blowing diecton ofthe nozzle iting device ‘Goneral information Speed "Swinging the miling unt up or downs” ‘Speed “Miling machine up or down" ‘Activation timing of he etches Height of he miling device with respec tothe miling plate Menu “Service techniclan* Calling up the menu "Service technician” ‘Strvetue ofthe menu "Service technic Processes inthe menu “Programming” Procesges inthe menu “Program correction” Processes inthe menu "Adjustments" Procesees inthe menu “Miling™ Processes inthe menu “Data management” Processes inthe menu “Disk operation™ Processes "PC Bit splay’, "Variant change" and "Languages" ‘Questioning the input and output signal ‘Changing the operating system Pneumatic maintenance unit 66 on 7 a 7% 7% 7 a 75 6 76 6 n n 7 n 20 e185 25 a 83,90 ot1. Sewing machine (cl. 805-121) 1.1 Hook, needle bar and needle guide 1.41 Loop stroke Explanation: The loop stoke isthe path ofthe nto bar rom I foner dead point fone pot, mere tne hook points at tne centre of the needa ue ‘The loop stoke should be 2 mm, Preparing the check and correction: Call up the menu “Moving he X. Y- and sew SrtSeloct he procoas*Lower sewing head and itn he tey <0" uron me imp had “Safety slop Stmetorsse0 8.54 check: = Mave the needle bar int ts bottom position Using the crank = With the Book (parts no, 981 15.000 2) press the gauge 2 pers no. 8st 15.0001) again the needle bar bushing and tighten the screw nthe block. = Pullout the gauge and turn the crank inthe a Fow-incleatedaiection unt the block rests ar oushing. ook point ust be atthe Comecton: Loosen the serews 3 and rotate the hook according: IWonthe deve shat 41.4.2 Needle bar height ute: Inthe loop stroke postion th hook point should be Ineateu i tne centre of he news sear. ‘Preparing the check and correction Call up the menu "Moving the X-, Y-and sowing fn olac he process “Lower Eowing oad” and ‘nt ne key "0" ura on tho lamp h40 “Saety stop Olthe motors", 600 8.5.4 chock Tum he eank accordingly. Correction: Loosen sorew «and shit the noodle bar according he 41.4.8 Hook pont - needle clearance ul: Inthe loop s1roce postion the clearance betwoen bk pent and needle scar should Be 0.1 mm, ‘Preparing the chock and correction Call up the meru "Moving the X-, Y- and sewing us elec roca Lowe Song ea tre tt no key “0 or-on the lamp MAO "Stety stop olthe motors" soe 8.5.4 hock: ‘Turn he rank accordingly. correction: ‘Loosen the serows 3 and analy shit the hook on fhe shat, 1.4.4 Needle guide - needle clearance Explanation ‘Wen sewing i certain crections the needle guide ‘should provent contac between the needle and hook pol. ae Inthe loop svoce poston the noodle quide § ‘shouldbe located ae clogs as possible tothe need ievthout touring t Proparng the chock and correction: Call up the monu "Moving the X-,¥- and sewing ‘bie’ eeloc! the process “Lower sewing head” and ‘with in key "0" turn on the lamp ha0 "Saety stop olihe motes", see 8.5.4 orecton: Loosen serew rand change the postion ofthe needle gue ® according Hint ‘Awcong adjustment may result in damage to the hook point andneedle breakage1.2 Bobbin case opener 41.2.1 Gener Information = The take-up lever must pul the thread between the cone part ana ts holder 2 To assure an Unninaered tread passage, the carve part Imust be opened a hat moment by tne bobbin Ease opene ‘The eared seam contouis thus sewn with @ minimum of tens tension. = Wrong adustments may resultin the fotowi “Treat breakages, se Loope a he matral underside High nolse eve 1.22 Height ofthe finger ae “The linger @ shouldbe a te same height with the Baleays cece te same Proparng the check ad correction: ‘Call up the menu “Moving te X,Y and sewing = the process Loner Sowing head and ‘the kay "0" turn on te lamp PO "Safty top ‘ithe motes", soe 9.8 heck “Tur the erank aocoringy correction Loosen serew 7 and tum the eccentric 5 accoraing: he 1.28. size ote pening orp - postion of the finger path ute: ‘The distance x between the opened contre part ‘Unde holder shou omespand othe sree eving tress, ‘Preparing the check and correction Call up te menu “Moving the X-,¥- and sown " SLower sewing nea and otthe motors", 600 8.3.4 neck ‘Turn he crank accordingly. correction {Loosen serew 6 and change the position ofthe fin- tera accoreingly 1.2.5 Depthof the fn ue ‘Te cistancs betwoon the tlnger 9 and centre part ‘Olsnould be approx. 0.5mm. (To aseure tat the tread passes unhindered be- ‘wean the finger and conto part) Preparing te check and correction: Callup the nana "Moving tne X,Y and seaing axis" Roloc the process ‘Lower sewing Nad” and shine Koy-6 fm toe tmp ha0“Saly top Sine mol’ s00 954 checks “Tur the crank accordingly. Correction Loosen screw 6 and adjust the finger 8 accordingly. (Nake sur not to change the opening path.) 2.6 Timing the opening motion rae As the tees ween the contre part 1 ‘thats hose the carta part tout be ope process "La wit he key 0" fur onthe lamp M40 “Sataty stop tthe mates, soe 85.4 cheek: Tuin the erank and watch the thread passage du fing swingPre-ajustment: = Loosen sorew 4 on the accent. = Move the needle bar to 1 mm ater ts upper Sea ange rank conn rocon ot ‘inne ve 3 using a sereweriver unt 8 i ats front turing pod, where the contre parts fully opened. = Tighten screw 4 onthe eccentric. correction = Loosen seraw 4 and accordingly change the positon ofthe eocentie 3 using a serewarver. i»\Wnen the bottom stroke positions asiuste, the ‘etance between the sowing ost al a iower dens point and the oat pits sneuld be. mm Preparing the check and correction: Call up the mons “Sewing ax” and select ho frocoss "lease sowing as, S00 92 neck = Adjust the bottom stroke position via ial 1 = Move the sewing fot int its botiom poston Using the crank Correction: Loosen serew 2and shit the cloth prosser bar 3 fscordingy Hint Whon the correction is completed, check the folloming conatons: Whon tho top stroke position is adjusted, the Noodle bat a its tower dead point must nat ouch 4.3.2 Timing of the sawing foot motion ke uh Siparmshaftcrank 101s ite same postion. Inte case batiite sewing oot and needs Dar reach ther Swer gag pont athe same colar of the eosenire 7 and the groove nthe shall shoulsbe 7 nm. ‘Preparing the check and correction: Cal up the manu "Movag ne X.Y and sory olathe provost “Lower sewing head” and them on he amp had Sa check: “Tur the erank accordingly. Correction Loosen screw 8 and change the postion of ho sto: Ke cccontie 7 on he sha accordingly, int ‘Awrong adjustment may have the fllowing consequences: strong vibrations othe sewing machi (Geceuze the sre eccontie 71s notin the ‘signated positon in reiaton fe tne count ‘wolght 8, thus causlng tne shaft to be unbalan- cea) ~ Skipped stiches1.4 Check spring ule: ‘Tne check spring should hav ust roachod is botiom positon, won tho nnedle Bas panstrated ‘he material up fs oye oneck ‘Sow with 5% of ho speed in the "Automate" cycle Correction of the path: = Slighty loosen serow 2 atthe arm. with he bot turn the entre thread tension ‘Besombiy accordingly. Correction ofthe tension = With the Key "0" tur on tho lamp N40 "Satety stop" = Loosen serow 2 atthe tivead tension assem. = Loosen serow 3 and tum the bolt 4 accordingly. mand pull out the 1.5. Thread tension release Explanation ‘he thea tension ie released magnetically during the toad tamming process. ale: “he tneeag must be pulled unhindered through the ‘eleased fenson, correction = With he key“0" turn on the lamp M40 *Satety stop = Loosen the soron 2 and change the poston of ire tonton assembly this, donot ton the fension) @°1.6 Oil lubrication ‘oll suppy tothe sewing “Tho hook crve shaft 5 conveys the ‘Sum va the spiral groaves through tn ine 4 fo {he wowing Road. The chock vave 8 nis tine ‘shoule prevent the ol rom running back at aching standett, The ol check tbe 2 above the Ine enables to check tho ol supply. certain. “amount af ho ol that conveyed tothe sewing fends sae to luoneate the machanieal part h ‘he soning oad. The remainder ofthe ol rune via line othe et pipe 3. From here, tho arm chat ‘bearing and the fot stoke mechanism are lobe {ea athe ol wicks ‘OiLrecitculation tothe sewing head Te accumulated olin the sowing head is cole {dat the bottom ol the sewing eee, where the ‘uetlbn line 14 wih the metal tors toca. Via {his ine the pump 10.00 the hook drive shall ecks Daexthe a ‘supp for he hook ‘The pump 10 doesnot only suck nthe ol rom the Turn the arm shaft in the sewing machine to the “ts positon” to nab to check “Tur the ar shat the sewing machine tothe “2nd position’ to able to cheek Activating the thread trimmer to check its unten. Determining the activation timing of he thread timmer and hus the “tat positon’ ‘On the sewing machine tore, 805-11 Move tho sith regulator into the postion for 2¢zag operation tobe Abie to correct cortainsojusiments.9.5.4 To make adjustments on the sewing machine make sure the motors are in “Safety stop” CCheck and correct the asjustments onthe sewing machine and thread immer only, ahem allots are dieablog using key "0" and aro thug In “Safety stop Sofey stops reachod when the lamp had “Salely stop is umincus ‘The nen-observance ofthis regulation may result in personal injury! Entry sequence Remarks / On-screen text (BT) Prerequisite Manu "Service technician’ ~ BT, tailed up S"Adlustments 1. Gallup menus Press key 3 - Br TiMoving X-, Y- and sewing exe 2, Call up menu" Press key 1 = Transfer pte tothe rear or owar sowing hoad 2. Gallup the proves. Sfower sowing rend’. Press the corresponding Menu "Moving sewing als called up key, 4. Motors to "Satoty stop": Turn on lamp N40 using toy9 5. Wnecessary. remove the For adjustment below the tabletop tabletop 6. Make the adjustments — See respective subjects eo9.5.5 Operating sequence withthe process “Single step mod: Entry sequence Remarks / On-screen text (87) Proroquisites: = Menu "Service ~ BT:3: Adjustments {echnican called up Lamp in key "on 1. Call up menu" = Press key 3 = BT2: Single stop mode 2, Select process 2": ~ Press key 2 BT: Stan and next stop: “Star 9. Call up stop: S 1 agotten When the folding process is completed the fllowing BT appears ary ‘Sar and new stop. Star™ Folaing: "Repetion” ‘Sewing: “Enable start 4. Torepeat he folding Bracess = Press kay 823 = The pans ofthe folding kit move back int hein poston. = BT Start and nox stop: "Start" ~ ross key bt as often as necessary 5. To.continue the cycle = Press key 0" = Press key bt as often ssneceesary 9.5.6 Operating sequence in the process *Gewing without fldingt Entry sequence Remarks / Onsor n text (BT) Voraussetzung: = Menu ‘Service technician’ — BT: 3: Adjustments ealled up 1. Gallup menus" ~ Prose kay BT'S: Sewing without folding 2. Select process = Prose key 3 = BT: Chango speed with > Contre sider down 3. Place the material undor 4. Start the sowing eye: = Press key bt e95.7 Calling up the operating data and, I necessary, changing them Operating sequence Remarks / On-screen text (BT) Prerequisite = Menu Service technica walled up 1. Gallup menu "3" Press key 3 - Bt 8: Operating date 2 Select niocess 6": Press koy "6° ~ 8, Stenting revolution (400): 400 2: Sttenos with start fev. (1)1 Bperating ime: Sewing time Number pieces: Siyie change ‘Ae modification: Tum off machine = Only the valves ofthe data marked with" and 2" ean be changed. “Theil values are desuces rom heute in brackets 00" 3. Techango tho valuos of wand 2" 5 key "1 or "2" = Change the value accordingly = Tuimoft the machine 96 Processes in the menu “Milling” For more information se subject 2 the programming manu Process Function / Remarks “Transtr plate’ = Miling the “sewing groove” = iting the bevel at both sides ofthe sowing groove ~ Double seams: Ming the 4 grooves that guide the inner sider “Centre sider = iting the outer contour ofthe upper andlowor sider plate = Mitig he “sight windows" inthe two slr plates “outer = iting the centering hols inthe outer an nner fame pate = iting the inner contour of he outer fame and outer contour ofthe n- “Front sie = Miting the contour ofthe font slider forth "round pocket styles rood! and"1800" “Hose inser = “Mitig the groove for the hose in this inset es8.7 Processes in the menu "Data management" For more information ee the subject 7 ofthe programming manuel Process Funetion/Remarks fete program” = Erasing the program inthe memory. Friis procese itis necessary to enter the counting number of the Fespective program, Should th be the number of base program, tithe belonging program varants wil also bs erased “Dispnypockat parameters" - Display ofthe folowing dlmensons or data aoe Posket goomety Promoter valde of he pocket and tack ‘Trantor late code ‘rinipocket parameters’ Printing te asplayed parameter values of m2 ealoa up pocket Braram is process is, however, only possilo, it a corresponding ntertace nists on to machine anda pate’ sala “avalsle pockats” = Using otal programs in the memory “doin programs” = oining2 or more pocket programs that only igh difer as regards - ‘heir geometry sothat they can be folded win ne ating ki ana “Dales jinng” = Re-deloting the joining of pocket programe9.8 Processes in the menu "Disk operation* For mre intermation se the subject 8 ofthe programming manus Process Function / Remarks “Dick ormattingt = ‘Preparing’ abrand:new cok o that data can be stored “Diredory" = Usting fall programs memorized on the disk *Dolote program” = Erasing the desired program irom the disk Ford process ie necessary fo erie te ruber of the vuspectve ine program, Should this be the numberof «basi program, Eeanging program variants wll also bo eased, “save program* = Tranafering the desired program irom the nachine memory tothe Giak in tho lek sve and stort on the disk ‘Rese program" — Transtering the dasied program trom the skin the disk rive to the machine memory. = Aprogram formed on @ machine can thus te transferred to another ‘achineva the procesces “Save program’ and Fad prog 9.9 Processes “PC-Bit-display", "Variant change" and "Languages cess Function / Remarks “Pc-bit play” ~ Questing ppt and ouput sana. “Variant change! = Selecting another vatlant ofthe respective basle program. “Languages = Solactng German, English, French, Spanish, Portuguese, Polish or Ratan on-sereen txts10. Questioning input and output signals Entry sequence: Remarks / On-screen text (8 Prerequisite: Menu “Service technician” =~ BT: up 7'3Pc-Bh apiay 1. Callup process “7 = Prose key "7" - or v0 90000006 39000000 19900000 2390000 3300000. 0000000. 0000000 300000 is inthe “outins ft sting represents the edaress slocted ‘cg eal up the umber in yea question the ouput signal yee. TO put sg Inthe Wo towor rows of iures with 2 digits exch, 0 represents ‘ignal not svalable® and represents “signal avaiable The Wiring iagrams show which signals are dlepayed wher, The signals avo clisplayed in each menu and dung exch function step, 2, Tequestion input signals ~ Gallup tho adsross "000" Using the kaye > ~ Determine the poston of iting dlagrams. thealepiay ‘Tho positon designation "0.3" or the signal “Sewing head down” 2 gles the folowing intormation OL Firat estat ow of figures 32th agit inthe raspactive row of figures Chock he display 3. Toquestion output eignae: = Call up he adcrass 064" Using the keys => ~ Determine tne positon — ofthe dapiay Check the display ing in the wing diagrams. 4. Todalate the signa anaplay ~ Call up the “Service ~ Gallup the menu Sorvige techician™ all up tne process SPe-Bh depiey" ee11. Changing the operating system ‘The RAM area does not only contain the machine specifications, which ae writen on the ns ‘or tor ine insertion ofthe dek ve, but sao the Sata o al pocket programs. Asal data Inthe RAM-area re oleted when he operating eysiom is changea tis advcable fo question all pocket program data or {eprint tnem witha pier. ok rive le avalbla, th data can also be transfered 10.8 dak ‘Operating sequence Remarks / On-screen toxt (81) Prerequisites: = Menu "Service technician’ selects - 5 Adjustments = Data ofthe pocket programs ether questioned - As deseribod in subjects 7-2, 7.9 and 6.40 he ‘rprinted otransterod toa dick programming manual - er, 5: Operating system 2. Select process“ . key 5° = Besides te sting ofthe machine specica- tions the flowing BT appears: ave a program bean saved Lo dak” 5. Compare the machine specications on the ad- ~The adhosWe label i onthe inside ol the cover Sete label wit the onscreen cata, and,ifné: 2 (page 80) forthe insertion o he disk drive essary, corect. = Compare the data = itnecessary,eottact the specications = Shoula the data dite, the specications onthe ‘adhesive label should be corrected 4, Answer questions and turn ofthe machine: ~ Press key "Yes" - Br Should the OS be changed now = Press key "Yee" ~ Br “Turn off machine = Tum off he main swten 3080 ‘Ghango the Eproms Pull out the contol unit Poll out th "la" Eproms fom the PO-board 1 Insert the new" Eproms Insen the conto unit “Tur onthe machine and select th language “Turn on the main switen Select the desired language wih the respoctve Koy Enir the machine specications ‘Call up the data using the manu key Enter the data Tun ofl the machin To do this, press down the stop plate Note the following Inser the Eproms wit he numbers 1-18 nto ‘Tho notches ofthe Eproms an sockets must ematehed 4 Spanish 5: italian Rie Ri As spectied onthe inside ofthe cover for the insertion fhe dak drive After entering the las value the following BT ‘Ton of machin Alter tuning on tho machine again, ether Fesform all progeame or road all programs trom the ois imo the macsine12, Pneumatic maintenance unit 12.1 Air filter and water separator Explanation ‘This unit 0.2 should separate dit partic fo elimrate blockages and fst formation nt roumatlesystom {The plastic sonar is blow-cleanod automatically va. Toaing valve, when a cerain water level has Boon reached Maintenance ‘Tho titer insert shouldbe cleaned evar tree ‘Montns with banzine of petaleum bofoe he leprossure crops. ~ Irate coment i spe wih shut = Vent the pneumatic system = Unscrow the plastic container = Unsecow te itr insert 12.2. Pressure reducing valve Explanation: ‘Ie pressure reducing valve 0.9 should duce the ressute of 7-10 bart tho operaling pressure Df bar to ebain constant paton speeds ana pling tres. {itn casoot 8 in pressure of move than 10 bar fnother pressure reducing valve must bs Sintaled use: ‘The operating pressure shouldbe 6 bar check Fad the ailusted pressure onthe manometer. Correction: Turn the button accordingly. 12.3. Mist lubricator Explanation: “The mist hbviestor 04 should supply all movable bars ofthe pneumatic systom wi alte reduce Sear and ftion forces and to proven eorosion. ute: = Alter every 5th machine cyto 1 drop shouts fall into the aie = The nozzle must bein the positon A = The al avel must be above the opening of the ution pipe. Correction: “To increase the supply quantity turn the screw in the direction s Toreduee tn supply quantity tun {he sorew inthe drection etiing: = Interrupt tha compressed ale supply with tho shutot valve = Vert he pneumatic system = Tum autho serow = ei he nya ol “ESO Nuto H 68° rary ‘ther ol with th folowing specications uo 10 fhe mark"mae" Viscosity at 400: 66 mm/s Flasnpont 238°C Maintenance: 9