Dürkopp Adler 650-10 Service Instructions Manual
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Dürkopp Adler 650-10 Service Instructions Manual

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  • Page 1 650-10 Service Instructions...
  • Page 2 IMPORTANT READ CAREFULLY BEFORE USE KEEP FOR FUTURE REFERENCE All rights reserved. Property of Dürkopp Adler AG and protected by copyright. Any reuse of these contents, including extracts, is prohibited without the prior written approval of Dürkopp Adler AG. Copyright © Dürkopp Adler AG 2016...

  • Page 3: Table Of Contents

    Change the thread tensioning spring.......... 48 3.22 Set the spring tension ..............50 3.23 Setting the spring travel .............. 51 3.24 Setting the thread regulator ............51 3.25 Winder ..................53 3.25.1 Setting the filling quantity............53 Service Instructions 650-10 - 01.0 - 08/2016...
  • Page 4 5.8.2 Reset Sewing Programs ............. 96 Test Input / Output ............96 5.10 Performing a software update ............ 96 5.11 Update machine software ............97 Maintenance ................103 Cleaning ................... 104 Lubricating ................105 Service Instructions 650-10 - 01.0 - 08/2016...
  • Page 5 Table of Contents Decommissioning..............107 Disposal................... 109 Technical data................. 111 Troubleshooting ..............113 10.1 Customer Service ..............113 10.2 Messages of the software............114 Errors in sewing process ............126 10.3 Appendix ................. 129 Service Instructions 650-10 - 01.0 - 08/2016...
  • Page 6 Table of Contents Service Instructions 650-10 - 01.0 - 08/2016...

  • Page 7: About These Instructions

    About these instructions About these instructions These instructions for the 650-10 have been prepared with utmost care. They contain information and notes intended to ensure long-term and re- liable operation. Should you notice any discrepancies or if you have improvement re- quests, then we would be glad to receive your feedback through Customer Service (...

  • Page 8: Other Documents

    The proper use of these components is described in each manufacturer's instructions. 1.4 Liability All information in these instructions was compiled with consideration to the state of the art, and applicable standards and regulations. Service Instructions 650-10 - 01.0 - 08/2016...
  • Page 9 Leave machines, equipment and packaging material in the condition in which they were found when the damage was discovered. This will ensure any claims against the transport company. Report all other complaints to Dürkopp Adler immediately after receiving the product. Service Instructions 650-10 - 01.0 - 08/2016...

  • Page 10: Service Instructions 650-10 - 01.0

    About these instructions Service Instructions 650-10 - 01.0 - 08/2016...

  • Page 11: Safety

    • set up the machine • carry out maintenance work and repairs • carry out work on electrical equipment Only authorized persons may work on the machine and they must first have understood these instructions. Service Instructions 650-10 - 01.0 - 08/2016...

  • Page 12: Signal Words And Symbols Used In Warnings

    If ignored, environmental damage can result NOTICE (without hazard symbol) If ignored, property damage can result The following symbols indicate the type of danger to personnel: Symbols Symbol Type of danger General Electric shock Service Instructions 650-10 - 01.0 - 08/2016...
  • Page 13 Type and source of danger! Consequences of non-compliance. Measures for avoiding the danger.  This is what a warning looks like for a hazard that could result in moderate or minor injury if the warning is ignored. Service Instructions 650-10 - 01.0 - 08/2016...
  • Page 14 NOTICE Type and source of danger! Consequences of non-compliance. Measures for avoiding the danger.  This is what a warning looks like for a hazard that could result in property damage if ignored. Service Instructions 650-10 - 01.0 - 08/2016...

  • Page 15: Individual Settings

    To lay the cables: 1. Lay any cable that is too long neatly in proper cable snakes. 2. Tie the snakes together using a cable tie. If possible, bind the snakes to fixed parts. Service Instructions 650-10 - 01.0 - 08/2016...

  • Page 16: Loosen Screws In Safety Covers

    (3) - Screws (2) - Tray Tilting the machine head To tilt the machine head: 1. Tilt the machine head (1) as far as it will go. 2. Loosen all five screws (3). Service Instructions 650-10 - 01.0 - 08/2016...

  • Page 17: Removing And Re-Fitting The Head Cover

    To dismount the head cover: 1. Loosen both screws (1). 2. Remove the head cover (2) Fitting the head cover To fit the head cover: 1. Fit the head cover (2). 2. Tighten both screws (1). Service Instructions 650-10 - 01.0 - 08/2016...

  • Page 18: Removing And Re-Fitting The Rear Arm Cover

    3.3.4 Removing and re-fitting the sewing material support and column cover Fig. 4: Removing and fitting the sewing material support and column cover (1) - Screws (3) - Sewing material support (2) - Column cover Service Instructions 650-10 - 01.0 - 08/2016...

  • Page 19: Removing And Inserting The Throat Plate

    To remove the throat plate: 1. Remove the material support and column cover ( p. 16). 2. Loosen the screws (4). 3. Remove the guide piece (3). 4. Remove the throat plate (7) upwards. Service Instructions 650-10 - 01.0 - 08/2016...

  • Page 20: Flats On Shafts

    Some shafts have flat surfaces at the points where the components are screwed on. This stabilizes the connection and makes adjustment easier. Important Always ensure that the screw faces are completely flush with the surface! Service Instructions 650-10 - 01.0 - 08/2016...

  • Page 21: Locking The Machine In Place

    • Reference position for the controller when the needle is in the lower dead center Positions 2, 3, and 5 are not allocated. Fig. 9: Lock the machine in place (2) (1) - Plug (3) - Locking peg (2) - Locking opening (4) - Marking Service Instructions 650-10 - 01.0 - 08/2016...

  • Page 22: Adjusting Hook And Needle Bar

    The loop stroke is the path length from the bottom dead center of the nee- dle bar up to the height where the hook is in the loop stroke position. The loop stroke of the 650-10 is 1.8 mm. Service Instructions 650-10 - 01.0 - 08/2016...
  • Page 23 • Damage to the hook • Damage to the needle • Missing stitches • Thread break Sequence Prerequisite: • A straight and undamaged needle must be used ( Operating Instructions, Changing the needle) Service Instructions 650-10 - 01.0 - 08/2016...

  • Page 24: Setting Loop Stroke And Hook Clearance

    Sequence After correcting the loop stroke position or the hook clearance, check the needle bar height ( p. 23). 6. Remove the locking mechanism ( p. 20). Service Instructions 650-10 - 01.0 - 08/2016...

  • Page 25: Setting The Needle Bar Height

    When doing this, take care not to twist the needle bar to one side! 4. Tighten the screw (1). Sequence After changing the needle bar height, check the loop stroke position and the hook clearance, as well ( p. 22). Service Instructions 650-10 - 01.0 - 08/2016...

  • Page 26: Setting The Thread Passage On The Middle Section Holder

    4. Tighten the setscrew (1). 3.10 Setting the throat plate Proper setting The needle must enter the needle hole on the throat plate precisely in the center. Faults caused by an incorrect setting • Incorrect stitch pattern Service Instructions 650-10 - 01.0 - 08/2016...

  • Page 27: Adjusting The Thread Cutter

    Machine is locked in place at Position 4 ( p. 17):  When you push the thread cutter lever (3) upwards, the roller (2) latches into place exactly in the small recess (1) of the control cam. Service Instructions 650-10 - 01.0 - 08/2016...
  • Page 28 (3) such that the roller (4) latches into place exactly in the small recess (1). 4. Tighten the control cam setscrews (5) without changing the position of the control cam. 5. Remove the locking mechanism ( p. 20). Service Instructions 650-10 - 01.0 - 08/2016...
  • Page 29 The armature of the thread cutter magnet must be completely extended! 4. Tighten the screw (2) of the thread cutter level (3) through the screw opening (6) in the housing without changing the position of the lever. Service Instructions 650-10 - 01.0 - 08/2016...

  • Page 30: Replacing And Setting The Thread-Pulling Knife

    5. Push the thread-pulling knife (3) forward onto the screws (2) as far as it will go. 6. Tighten the screws (2). 3.11.3 Changing the counter blade Cover • Remove the material support and column cover ( p. 16) Service Instructions 650-10 - 01.0 - 08/2016...

  • Page 31: Setting The Counter-Blade And Cutting Pressure

    • Threads are cut too long Cover • Tilt the machine head ( p. 14) • Remove the material support and column cover ( p. 16) • Removing the throat plate ( p. 17) Service Instructions 650-10 - 01.0 - 08/2016...

  • Page 32: Setting The Path Of The Thread-Pulling Knife

    • Threads are cut too long Cover • Tilt the machine head ( p. 14) • Remove the material support and column cover ( p. 16) • Removing the throat plate ( p. 17) Service Instructions 650-10 - 01.0 - 08/2016...

  • Page 33: Set The Middle Foot

    Proper setting The correct height of the middle foot depends on the thickness of the sewing material: • Thick material: Set the middle foot higher • Thin material: Set the middle foot lower Service Instructions 650-10 - 01.0 - 08/2016...

  • Page 34: Adjusting The Toothed Belt

    3.15.1 Toothed belt between upper and lower shaft Proper setting At the front strand, the tension of the toothed belt is 60 – 80 Hz. Cover • Tilt the machine head ( p. 14) Service Instructions 650-10 - 01.0 - 08/2016...

  • Page 35: Toothed Belt For Hook Drive

    The toothed belt has a clearance of 1 mm from the retaining rings on the lower toothed belt pulley. Cover • Tilt the machine head ( p. 14) • Remove the material support and column cover ( p. 16) Service Instructions 650-10 - 01.0 - 08/2016...
  • Page 36 4. Loosen the setscrews (6) for the large toothed belt pulley (5). 5. Align the toothed belt pulleys: • Move the lower toothed belt pulleys (4) together with their axes • Move the large toothed belt pulley (5) on the shaft Service Instructions 650-10 - 01.0 - 08/2016...
  • Page 37 9. Tighten the screws on the front and rear of the cover. Sequence Check the following setting after completely re-fitting the toothed belt or loosening the large toothed belt pulley: • Position of the hook ( p. 22) Service Instructions 650-10 - 01.0 - 08/2016...

  • Page 38: Replacing And Setting The Top Conveyor Belts

    7. Push the left sewing foot upwards and the right sewing foot downwards. 8. Remove the right conveyor belt from the sewing foot. 9. Remove the right conveyor belt from the gear wheel (6) and from the guide (5). Service Instructions 650-10 - 01.0 - 08/2016...

  • Page 39: Setting The Top Conveyor Belts

    The jump protection must not impede the course of the right conveyor belt. The correct distance between the jump protection and the right conveyor belt is 0.2 – 0.3 mm. Service Instructions 650-10 - 01.0 - 08/2016...
  • Page 40 2. Turn the appropriate eccentric screw (1) with a flat-head screwdriver in order to change the tension. 3. Tighten the screws (2). 4. Perform steps 1 – 3 for the other conveyor belt. Service Instructions 650-10 - 01.0 - 08/2016...

  • Page 41: Replacing And Setting The Bottom Conveyor Belts

    2. Remove both conveyor belts (2) from the bottom gear wheel (5). 3. Pull the conveyor belts (2) upwards through the base plate cutout (3). 4. Remove both conveyor belts from the gear rims on the throat plate (1) one after the other. Service Instructions 650-10 - 01.0 - 08/2016...

  • Page 42: Setting The Bottom Conveyor Belts

    • Increased wear of belts Information Test possibilities for the stepper motors of the conveyor belts can be found in the software: • OP3000 (Multitest->Test Step Motor,  p. 69) • OP7000 (not possible at this time) Service Instructions 650-10 - 01.0 - 08/2016...

  • Page 43: Replacing The Gear Rims

    3.18 Replacing the gear rims Cover • Tilt the machine head ( p. 14) • Remove the material support and column cover ( p. 16) • Removing the throat plate ( p. 17) Service Instructions 650-10 - 01.0 - 08/2016...

  • Page 44: Checking The Sewing Foot Lifting Gear

    • Sewing foot ventilation • Sewing foot calibration Checking for mechanical problems 1. Dismount the lifting gear as described below. 2. Check components for defects. 3. Fit the lifting gear as described below. Service Instructions 650-10 - 01.0 - 08/2016...
  • Page 45 6. Remove electric thread tensioner in order to gain access to the bearing point in the right lifting gear ( p. 45). You do not need to remove the thread tensioner cables from the plug to do this. Service Instructions 650-10 - 01.0 - 08/2016...
  • Page 46 3. Insert the electric thread tensioner ( p. 45). Important Make sure you do not damage the cables and you properly lay cables that are too long when inserting the thread tensioner! 4. Tighten the screws (2). Service Instructions 650-10 - 01.0 - 08/2016...

  • Page 47: Dismounting And Fitting Electric Thread Tensioner

    • OP3000 ( p. 70) • OP7000 ( p. 93) 3.20 Dismounting and fitting electric thread tensioner Cover • Head cover ( p. 15) • Rear arm cover ( p. 16) Service Instructions 650-10 - 01.0 - 08/2016...
  • Page 48 Only when installing a new thread tensioner: 4. Remove the cable shoe (4) from the transparent plug (3) on the rear of the stepper motor. 5. Carefully remove the thread tensioner (1) forwards together with the cables. Service Instructions 650-10 - 01.0 - 08/2016...
  • Page 49 • OP3000 ( p. 70) • OP7000 ( p. 93). Set the thread tension for thread cutting using the software: • OP3000 ( p. 62) • OP7000 ( p. 87) Service Instructions 650-10 - 01.0 - 08/2016...

  • Page 50: Change The Thread Tensioning Spring

    6. Loosen the thread tensioning spring (7) from the cylinder. To do so, use a screwdriver to remove the spring thread from the inner part. 7. Pull the open end of the thread tensioning spring through the slot (6). Service Instructions 650-10 - 01.0 - 08/2016...
  • Page 51 Important Leave the tension disks on the tension bolt! If the tension disks have been removed, recalibrate the thread tension using the software: • OP3000 ( p. 70) • OP7000 ( p. 93) Service Instructions 650-10 - 01.0 - 08/2016...

  • Page 52: Set The Spring Tension

    To set the spring tension: 1. Dismount electrical thread tensioner ( p. 45). 2. Loosen the setscrew (1). 3. Pull the inner cylinder (2) out of the thread tensioner. 4. Loosen the setscrew on the cylinder (3). Service Instructions 650-10 - 01.0 - 08/2016...

  • Page 53: Setting The Spring Travel

    The thread regulator determines the needle thread quantity to be guided around the hook. The required thread quantity depends on the thickness of the sewing material, the thread strength, and the stitch length. Service Instructions 650-10 - 01.0 - 08/2016...
  • Page 54 3. Move the thread regulator (1): • Move the regulator to the left = greater thread quantity • Move the regulator to the right = lower thread quantity 4. Tighten the screw (2). Service Instructions 650-10 - 01.0 - 08/2016...

  • Page 55: Winder

    1. Loosen the adjusting screw (1). 2. Move the thread guide plate (3): • Move towards the bobbin = smaller filling quantity • Move away from the bobbin = larger filling quantity 3. Tighten the adjusting screw (1). Service Instructions 650-10 - 01.0 - 08/2016...

  • Page 56: Setting The Winder Winding Form

    3.25.3 Setting the winding tension Proper setting The correct tension during winding depends on the sliding properties and the thickness of the thread. Fault • Ruffling on the seam • Incorrect stitch pattern Service Instructions 650-10 - 01.0 - 08/2016...

  • Page 57: Service Settings Via Software (Op3000)

    The numbers are not shown for reasons of security. A 0 appears at the relevant entry point; aster- isks are in the other positions. / to move from one entry point to another. Service Instructions 650-10 - 01.0 - 08/2016...

  • Page 58: Menu Items At The Technician Level

    : Reset machine to delivery state ( p. 74) 4.2 Menu items at the Technician level The following table provides an overview of the structure of the service menu. Magenta: Menu items for settings and information used by technicians Service Instructions 650-10 - 01.0 - 08/2016...
  • Page 59  p. 60 Default Presettings which are program applicable to all sewing Stitchlen. programs Curve Foot Press. Thr. Tens. FullnessType Fullness Foot Stroke Start Tack End Tack 1.10 Thread Trim 1.11 Teach Side 1.12 Action Service Instructions 650-10 - 01.0 - 08/2016...
  • Page 60 Pos. Speed 2.4.4 Soft Speed 2.4.5 N Stitches Stop Positions 2.5.1 StopIdle° 2.5.2 StopTop° 2.5.3 StopBottom° Foot 2.6.1 FL AtStop 2.6.2 FL AfterTrim 2.6.3 FL height Thr. Tens. 2.7.1 PreTension 2.7.2 t After Sew Service Instructions 650-10 - 01.0 - 08/2016...
  • Page 61 N Steps Pedal 2.8.5 t Posit. 0 2.8.6 t Posit. -1 2.8.7 t Posit. -2  p. 66 User config. Define advanced machine settings Language Forward Sound AutoForw Side Pedal Abort Pedal 2 Brightness Contrast Service Instructions 650-10 - 01.0 - 08/2016...

  • Page 62: Menu Item Default Program

    Define the preset values as follows: 1. Select Default Program in the service menu.  The following appears on the display: Fig. 47: Menu item Default Program 001-999 Service Instructions 650-10 - 01.0 - 08/2016...
  • Page 63 1 sleeve side sleeve side mirror = mirror to create the 2 sleeve sleeve side side teach = program sleeve side ask = selection mask for nothing, mirror or teach Service Instructions 650-10 - 01.0 - 08/2016...

  • Page 64: Menu Item Machine Config

    The submenu End Tack matches the submenu Start Tack ( p. 62). You can adjust the same settings here for the end bartack. 4.4.3 Thread Trim In the submenu Thread Trim, you can define the settings for cutting the thread. Service Instructions 650-10 - 01.0 - 08/2016...

  • Page 65: Speed

    Minimum speed in min Pos. Speed Speed when positioning 10 – 700 in min Soft Speed 10 – 1000 Speed on soft start in min N Stitches Number of soft start stitches 1 – 10 Service Instructions 650-10 - 01.0 - 08/2016...

  • Page 66: Stop Positions

    0 = off sewing stops 1 = on FL AfterTrim Sewing foot rises after 0 = off cutting the thread 1 = on FL height Sewing foot position when 5 – 14 raised Service Instructions 650-10 - 01.0 - 08/2016...

  • Page 67: Thr. Tens

    0 – 64 pedal t Posit. 0 Debouncing of position 0 0 – 255 t Posit. -1 Debouncing of position -1 0 – 255 t Posit. -2 Debouncing of position -2 0 – 255 Service Instructions 650-10 - 01.0 - 08/2016...

  • Page 68: Menu Item User Config

    Function of the optional ~ = Modification ± additional pedal of fullness Curve = Modifi- cation of curve support Brightness Control panel brightness 0 – 255 Contrast Control panel contrast 0 – 255 Service Instructions 650-10 - 01.0 - 08/2016...

  • Page 69: Menu Item Service

    To test the magnets for the thread cutter: / 1. Use in the field to choose the element that you wish to test: • 2 = Thread cutter magnet Fig. 57: Test PWM Service Instructions 650-10 - 01.0 - 08/2016...
  • Page 70 In the submenu Test Auto Input, you can carry out the same tests as under Test Input without having to select the element beforehand via the display. Fig. 59: Test Auto Input – AUTO Service Instructions 650-10 - 01.0 - 08/2016...
  • Page 71 Stepper 2. Press the OK key. / 3. Use to test the respective motor.  If the motor is functioning correctly, the behavior described in the table will be shown. Service Instructions 650-10 - 01.0 - 08/2016...

  • Page 72: Calibration

    9. Step on the pedal and observe the feed rate of the boards:  Both boards must be fed without offset. If the boards are not fed without offset, correct the differential top feed. Service Instructions 650-10 - 01.0 - 08/2016...
  • Page 73  The machine will calibrate automatically: Both sewing feet will lift once and then lower again. The calibration is then complete. Thread Calib In the submenu Thread Calib, you can calibrate the thread tension. Service Instructions 650-10 - 01.0 - 08/2016...
  • Page 74 2. After the thread lever, feed the thread into the measurement device. / 3. Use to select calibration position 3. Fig. 65: Thread Calib., Set calibration position 3 (1) F = 300g 4. Press the OK key. Service Instructions 650-10 - 01.0 - 08/2016...
  • Page 75 1. 2. Press the OK key. / 3. Use to change the thread tension until the measurement device displays a value of 5 g. 4. Press the OK key. Service Instructions 650-10 - 01.0 - 08/2016...

  • Page 76: Reset

     All the sewing programs you have created yourself will be deleted. The standard programs will be returned to their delivery state. Reset all In the submenu Reset All, you can reset all sewing programs and parameters to the delivery state. Service Instructions 650-10 - 01.0 - 08/2016...

  • Page 77: Data Transfer

    When a new software version is available, you can download it from the website of Dürkopp Adler and load it using a USB stick. All settings on the machine are retained. The  Additional Instructions describe how to perform a software update. Service Instructions 650-10 - 01.0 - 08/2016...

  • Page 78: Testing The Functionality Of The Keys On The Control Panel

    5. Press the OK key. • If one or several keys are not functional:  The status report Keys … NOT OK! appears on the display. The control panel has to be replaced. Service Instructions 650-10 - 01.0 - 08/2016...

  • Page 79: Update Machine Software

    1. Download the machine-specific update from the Dürkopp Adler website (https://software.duerkopp-adler.com/maschinenprogramme.html).  The program is packed in a .zip-file, the name consists of the part number of the program, the software version and the date, i. e. 9899_080600_000_A01.0.4_2013-12-10.zip Service Instructions 650-10 - 01.0 - 08/2016...
  • Page 80  The update starts. The LEDs (4) light up.  The update is finished when only the POWER LED glows. Important 5. Calibrate the electronic thread tension ( p. 65).  The machine is ready to sew. Service Instructions 650-10 - 01.0 - 08/2016...

  • Page 81: Service Settings Via Software (Op7000)

    The numbers are not shown for reasons of security. A 0 appears at the relevant entry point; asterisks are in the other positions. 3. Tap the OK button. Service Instructions 650-10 - 01.0 - 08/2016...

  • Page 82: Menu Items At The Technician Level

    Fig. 72: Display in service menu 5.2 Menu items at the Technician level The following table provides an overview of the structure of the service menu. Magenta: Menu items for settings and information used by technicians Service Instructions 650-10 - 01.0 - 08/2016...
  • Page 83 Curve Intensity Foot Pressure Thread Tension Fullness Top/Bottom Fullness Foot Stroke Alternation Backtack At Start Backtack At End 1.10 Thread Trimmer 1.11 Size 1.12 Seam Graphic 1.13 Grading Factor 1.14 Teach Side (L=1/R=2) Service Instructions 650-10 - 01.0 - 08/2016...
  • Page 84 Backward 2.2.4 Number Stitches Forward 2.2.5 Speed Thread Trimmer 2.3.1 Speed 2.3.2 Thread Tension 2.3.3 Turn Backward After Trimming Speed 2.4.1 Maximum Speed 2.4.2 Positioning Speed 2.4.3 Softstart Speed 2.4.4 Number Stitches Softstart Service Instructions 650-10 - 01.0 - 08/2016...
  • Page 85  p. 91 Transfer data with a USB Operations Write Active Sewing Program To USB Read Sewing Program From Write Global Data Of Control Unit To Overwrite Global Data Of Control Unit With USB Data Service Instructions 650-10 - 01.0 - 08/2016...

  • Page 86: Menu Item Default Program Parameters

    Define the preset values as follows: 1. Select Default Program Parameters in the service menu.  The following appears on the display: Service Instructions 650-10 - 01.0 - 08/2016...
  • Page 87 2 = bottom Fullness Fullness 0 – 16 Foot Stroke Alternation: 0 – 2.5 Alternation The sewing foot is lifted by this height for each stitch Backtack Start bartack 0 – 1 At Start Service Instructions 650-10 - 01.0 - 08/2016...
  • Page 88 Grading Factor Grading factor as a percent- 0.0 – 6.0 age, increase from size to size Teach Side Sleeve side which is 2 = R (start with (L=1/R=2) programmed first right sleeve) 1 = L (start with left sleeve) Service Instructions 650-10 - 01.0 - 08/2016...

  • Page 89: Menu Item Machine Configuration

    Number Stitches Number of backward 1 – 50 Backward stitches per bartack Number Stitches Number of forward stitches 1 – 50 Forward per bartack Speed Speed when sewing the 50 – 2000 1000 bartack Service Instructions 650-10 - 01.0 - 08/2016...

  • Page 90: Thread Trimmer

    Speed on soft start in min Number Stitches Number of soft start stitches 0 – 10 Softstart 5.4.4 Stop Positions In the submenu Stop Positions, you can determine the position of the needle when sewing stops. Service Instructions 650-10 - 01.0 - 08/2016...

  • Page 91: Foot

    Foot Lift At Seam Sewing foot lifting at the end 0 = off of the seam 1 = on (after cutting the thread) Position Foot Up Sewing foot position when 5 – 14 raised Service Instructions 650-10 - 01.0 - 08/2016...

  • Page 92: Menu Item User Configuration

    Function of the optional 0 = Additional additional pedal pedal without function 1 = Modification of fullness 2 = Modification of curve support 6 = Fullness -2 – 7 7 = Fullness -2 – 16 Service Instructions 650-10 - 01.0 - 08/2016...

  • Page 93: Menu Item Usb Operations

    Load sewing program from USB stick Write Global Data Of Control Transfers all files to a USB stick Unit To USB Overwrite Global Data Of Transfer all data from USB stick Control Unit With USB Data Service Instructions 650-10 - 01.0 - 08/2016...

  • Page 94: Menu Item Calibration

    2. Change to manual mode MAN ( Operating Instructions). 3. Set fullness = 0 and stitch length = 2. 4. Allow 2 PTFE strips to run through with the fabric side outwards. The strips should be fed without offset. Service Instructions 650-10 - 01.0 - 08/2016...

  • Page 95: Feet Difference Calibration

    2. After the thread lever, feed the thread into the thread tension measurement device. 3. Select Tension Top 300g. 4. Press On/Off.  The tension element is closed. 5. Measure the tension value. It must be at 300 g. Service Instructions 650-10 - 01.0 - 08/2016...
  • Page 96 Set calibration position 1 as follows: 1. Select Tension Top 5g. 2. Change the thread tension with +/-1 or +/-10, until the thread tension measurement device displays a value. 3. Exit the menu item. Service Instructions 650-10 - 01.0 - 08/2016...

  • Page 97: Menu Item Reset Operations

    5.8.1 Reset All In the submenu Reset All, you can reset all sewing programs and pa- rameters to the delivery state. Only the calibration values for the thread tension and sewing feet are retained. Service Instructions 650-10 - 01.0 - 08/2016...

  • Page 98: Reset Sewing Programs

    When a new software version is available, you can download it from the website of Dürkopp Adler and load it using a USB stick. All settings on the machine are retained. The  Additional Instructions describe how to perform a software update. Service Instructions 650-10 - 01.0 - 08/2016...

  • Page 99: Update Machine Software

    This is how you perform the software update: 1. Download the update file from the Dürkopp Adler website. The file is named 9899_65500_700_A03.61_2016-08-15.jcbi 2. Copy the update file on a Dürkopp Adler USB key (part number 9835 301003). Service Instructions 650-10 - 01.0 - 08/2016...
  • Page 100 Fig. 82: Update machine software (3)  The update will take approx. 2 minutes. Important Do not switch off the machine during the update!  Remove the USB key when prompted to do so. Service Instructions 650-10 - 01.0 - 08/2016...
  • Page 101  The machine shows notice 8403: Machine has an out-dated pro- gram. Should a new program be transmitted? Fig. 84: Update machine software (5) 6. Confirm with OK.  The update is carried out. Service Instructions 650-10 - 01.0 - 08/2016...
  • Page 102 Do not switch off the machine during the update!  The display shows notice 8408: Waiting for reset by machine ... Fig. 86: Update machine software (7)  The machine restarts automatically.  After restarting, the machine loads the start screen. Service Instructions 650-10 - 01.0 - 08/2016...
  • Page 103  The following warning appears: Fig. 87: Update machine software (8)  After confirming with OK, you can continue working with the old machine software. Important Using out-dated software may lead to serious problems. Service Instructions 650-10 - 01.0 - 08/2016...
  • Page 104 Service settings via software (OP7000) Service Instructions 650-10 - 01.0 - 08/2016...

  • Page 105: Maintenance

     Clean engine fan filter  Check the upper and lower conveyor belts for wear  Check sewing foot for wear  Lubricate the joints on the gear  Lubricating the needle bar Service Instructions 650-10 - 01.0 - 08/2016...

  • Page 106: Cleaning

    Solvent-based cleaners may damage paintwork on the machine. Only use solvent-free substances for wiping the machine. Clean the machine as follows: 1. Remove any lint and thread remnants using a compressed air pistol or a brush. Service Instructions 650-10 - 01.0 - 08/2016...

  • Page 107: Lubricating

    Carefully collect up used oil. Dispose of used oil and oily machine parts in accordance with the legal regulations. Abb. 89: Lubricating (1) - Joint on the gear (2) - Needle bar Service Instructions 650-10 - 01.0 - 08/2016...
  • Page 108 Maintenance Service Instructions 650-10 - 01.0 - 08/2016...

  • Page 109: Decommissioning

    4. Cover the operating panel to protect it from contamination. 5. Cover the controller to protect it from soiling. 6. Cover the entire machine if possible to protect it from contamination and damage. Service Instructions 650-10 - 01.0 - 08/2016...
  • Page 110 Decommissioning Service Instructions 650-10 - 01.0 - 08/2016...

  • Page 111: Disposal

    When disposing of the machine, be aware that it consists of a range of dif- ferent materials (steel, plastic, electronic components, etc.). Observe the applicable national regulations when disposing of these materials. Service Instructions 650-10 - 01.0 - 08/2016...
  • Page 112 Disposal Service Instructions 650-10 - 01.0 - 08/2016...

  • Page 113: Technical Data

    [min Clearance under the raised sewing foot [mm] max. 12 Material thickness [mm] max. 4 Mains voltage Mains frequency [Hz] Table height [mm] 750 – 900 Length, width, height [mm] 750/1320/1490 Weight [kg] Service Instructions 650-10 - 01.0 - 08/2016...
  • Page 114 Technical data Service Instructions 650-10 - 01.0 - 08/2016...

  • Page 115: Troubleshooting

    Contact for repairs and issues with the machine: Dürkopp Adler AG Potsdamer Str. 190 33719 Bielefeld, Germany Tel. +49 (0) 180 5 383 756 Fax +49 (0) 521 925 2594 E-Mail: service@duerkopp-adler.com Internet: www.duerkopp-adler.com Service Instructions 650-10 - 01.0 - 08/2016...

  • Page 116: Messages Of The Software

    • Replace the sewing motor • Contact customer service 1007 Error Error in the reference run • Replace the encoder • Eliminate stiff movement in the machine 1008 Error Sewing motor encoder error • Replace the encoder Service Instructions 650-10 - 01.0 - 08/2016...
  • Page 117 • Contact customer service 1062 Error Sewing motor fault • Switch the machine off and on (IDMA auto increment) again 1120 Error Software error: • Perform a software update • Parameter not initialized Service Instructions 650-10 - 01.0 - 08/2016...
  • Page 118 • Stepper motor defective • Replace the stepper motor • Controller defective • Replace the control 2162 Error X-axis stepper motor fault • Switch the machine off and on (IDMA auto increment) again Service Instructions 650-10 - 01.0 - 08/2016...
  • Page 119 Stepper motor overcurrent • Replace the sewing motor cable • Replace the stepper motor • Replace the control 2184 Error Software error • Perform reset • Perform a software update • Contact customer service Service Instructions 650-10 - 01.0 - 08/2016...
  • Page 120 Y-axis stepper motor: • Correct the cause of not moving • Stepper motor not moving freely freely • Stepper motor defective • Replace the stepper motor • Controller defective • Replace the control Service Instructions 650-10 - 01.0 - 08/2016...
  • Page 121 • Check the encoder cable and replace, if necessary • Replace the stepper motor 2283 Error Stepper motor overcurrent • Replace the sewing motor cable • Replace the stepper motor • Replace the control Service Instructions 650-10 - 01.0 - 08/2016...
  • Page 122 • Remove the blockage or the cause • Stepper motor not moving freely of the stiff movement or blocked • Replace the stepper motor • Stepper motor defective • Replace the control • Controller defective Service Instructions 650-10 - 01.0 - 08/2016...
  • Page 123 Error in the reference run • Replace the reference switch 2382 Error Stepper motor current error • Remove the blockage • Check the encoder cable and replace, if necessary • Replace the stepper motor Service Instructions 650-10 - 01.0 - 08/2016...
  • Page 124 U-axis stepper motor not • Perform a software update responding • Replace the control 2452 Error U-axis stepper motor over current • Replace the stepper motor 2453 Error Excess voltage • Check the mains voltage Service Instructions 650-10 - 01.0 - 08/2016...
  • Page 125 • Replace the encoder • Check plug assignment and change, if necessary • Check wiring in machine distributor and change it, if necessary • Test stepper motor phases and check for correct value Service Instructions 650-10 - 01.0 - 08/2016...
  • Page 126 • Replace the control 3030 Error Sewing motor phase error • Test sewing motor phases (R = 2,8 Ω, high impedance to PE) • Replace the encoder • Replace the sewing motor • Replace the control Service Instructions 650-10 - 01.0 - 08/2016...
  • Page 127 • Replace the cable • Contact customer service 9910 Error Tilt sensor: • Erecting the machine head • Machine head is tilted over • Fit or replace tilt sensor • Tilt sensor not fitted or defective Service Instructions 650-10 - 01.0 - 08/2016...

  • Page 128: Errors In Sewing Process

    • Incorrect parts used for the • Check the parts based on the desired sewing equipment equipment sheet • Needle plate, hook or spread • Have parts reworked by qualified have been damaged by the personnel needle Service Instructions 650-10 - 01.0 - 08/2016...
  • Page 129 • Needle thickness is unsuitable • Use recommended needle Breakage for the sewing material or the thread Seam • Residual tension is too tight for • Adjust residual tension beginning not the needle thread secure Service Instructions 650-10 - 01.0 - 08/2016...
  • Page 130 Troubleshooting Service Instructions 650-10 - 01.0 - 08/2016...

  • Page 131: Appendix

    Appendix 11 Appendix Fig. 90: Interconnection diagram, sheet 1 Service Instructions 650-10 - 01.0 - 08/2016...
  • Page 132 Appendix Fig. 91: Interconnection diagram, sheet 2 Service Instructions 650-10 - 01.0 - 08/2016...
  • Page 133 Appendix Fig. 92: Interconnection diagram, sheet 3 Service Instructions 650-10 - 01.0 - 08/2016...
  • Page 134 Appendix Fig. 93: Interconnection diagram, sheet 4 Service Instructions 650-10 - 01.0 - 08/2016...
  • Page 135 Appendix Fig. 94: Interconnection diagram, sheet 5 Service Instructions 650-10 - 01.0 - 08/2016...
  • Page 136 Appendix Fig. 95: Interconnection diagram, sheet 6 Service Instructions 650-10 - 01.0 - 08/2016...
  • Page 137 Appendix Fig. 96: Interconnection diagram, sheet 7 Service Instructions 650-10 - 01.0 - 08/2016...
  • Page 138 Appendix Service Instructions 650-10 - 01.0 - 08/2016...
  • Page 140 DÜRKOPP ADLER AG Potsdamer Straße 190 33719 Bielefeld GERMANY Phone +49 (0) 521 / 925-00 E-mail service@duerkopp-adler.com www.duerkopp-adler.com...

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