DURKOPP ADLER 806 Service Instructions Manual
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DURKOPP ADLER 806 Service Instructions Manual

DURKOPP ADLER 806 Service Instructions Manual

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See also: Instruction and Installation Manual
Contents:
Part 3: Service Instructions class. 806
1.
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.
2.1
Stitch regulator and transmission lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.1.1
0-position of the stitch regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.1.2
Position of the transmission lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.2
Rocker and throat plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.2.1
General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.2.2
Position of the rocker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.2.3
Timing the rocker oscillation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.2.4
Range of the rocker oscillation (throw width) . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.2.5
Horizontal position of the throat plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.2.6
Height of the throat plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.3
Adjusting the bobbin winder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.4
Hook, needle bar, hook guard and needle guide . . . . . . . . . . . . . . . . . . . . . . . . .
2.4.1
Loop stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.4.2
Sliding clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.4.3
Needle bar height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.4.4
Distance between the hook and the needle . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.4.5
2.5
2.5.1
General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.5.2
Amount of the finger travel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.5.3
Amount of the lifting gap (position of the finger travel) . . . . . . . . . . . . . . . . . . . . . .
2.5.4
Timing the bobbin case lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.6
Sewing foot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.6.1
General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.6.2
Timing the sewing foot movement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.7
Thread take-up spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.8
Lifting the thread tensioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.9
Thread advancing device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.10
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.10.1
General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.10.2
Mode of function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.10.3
Checking oil level and oil supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.10.4
2.10.5
Oil change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.10.6
2.11
Sewing arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.11.1
General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.11.2
Lower position of the arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.11.3
2.11.4
Damping the cylinder in its end position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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Summary of Contents for DURKOPP ADLER 806

  • Page 1: Table Of Contents

    Contents: Page: Home Part 3: Service Instructions class. 806 General ..........Machine head (Class 806-111) Stitch regulator and transmission lever .
  • Page 2 Contents: Page: 2.12 Thread cutter ..........2.12.1 Sequence of functions .
  • Page 3 Contents: Page: Folding device Outer frame ..........4.1.1 General information .
  • Page 4 Contents: Page: Transfer carriages General information ........Adjusting the parallelism of the transfer plate .

  • Page 5: General

    General The present Service Manual describes the sequence to be respected when adjusting the sewing unit. ATTENTION ! The different adjustment positions are interdependent. Therefore, all adjustments must be made in the described sequence. ATTENTION ! The actions described in the present Manual must be carried out exclusively by specialists or by the properly qualified persons! Danger of breakage ! Before restarting the machine that has been dismounted, first carry out...

  • Page 6: Machine Head (Class 806-111)

    Machine head (Class 806-111) Stitch regulator and transmission lever 2.1.1 0-position of the stitch regulator Caution: Danger of bodily injuries ! The machine must be in the position "Safe motor stop " . Rule and control The needle bar should not ”oscillate” when sewing without zigzag function.

  • Page 7: Position Of The Transmission Lever

    2.1.2 Position of the transmission lever The lever 2 transmits the motion of the feed shaft 3 to the rocker 1. Caution: Danger of bodily injuries ! The machine must be in the position "Safe motor stop". Rule and control The lever 2 should be in vertical position when the zigzag function is snot activated.
  • Page 8 10 11 12 13 14 15...

  • Page 9: Rocker And Throat Plate

    Rocker and throat plate 2.2.1 General information While the needle bar and the throat plate are performing a complete oscillation movement during the zigzag function, the needle bar will move 2 times up and down.. This is ensured by the couple of gears 1 and 2, having a transmission ratio of 1 : 2..

  • Page 10: Timing The Rocker Oscillation

    2.2.3 Timing the rocker oscillation Caution: Danger of bodily injuries ! Do not introduce your hands into the moving machine parts. Rule and control – In the zigzag mode, when stitching into the upper bartack point, the needle should be ”driven inwards to the same extent as it is driven when stitching into the lower.

  • Page 11: Range Of The Rocker Oscillation (Throw Width)

    2.2.4 Range of the rocker oscillation (throw width) Caution: Danger of bodily injuries ! The machine must be in the position "Safe motor stop ". Rule and control In the zigzag mode of the machine, the "upper" and the "lower" stitches on a piece of paper should have a distance of 5 mm.

  • Page 12: Horizontal Position Of The Throat Plate

    2.2.5 Horizontal position of the throat plate Caution: Danger of bodily injuries ! The machine must be in the position "Safe motor stop ". Rule and control – In X-direction: In the loop formation position – or a bit later – the needle shank 2 should be distanced 0.3 mm from the right side of the stitch hole 1.

  • Page 13: Height Of The Throat Plate

    2.2.6 Height of the throat plate Caution: Danger of bodily injuries ! The machine must be in the position "Safe motor stop ". Rule and control The stitch hole mushroom button must stand 0,5 mm under the top of the fabric rest. Correction –...

  • Page 14: Adjusting The Bobbin Winder

    2.3 Adjusting the bobbin winder Rule and control The bobbin winder should stop automatically when the bobbin when the thread wound on the bobbin is about 0,5 mm from its rim. The thread should be wound cylindrically. Caution: Danger of bodily injuries ! The machine must be in the position "Safe motor stop ".

  • Page 15: Hook, Needle Bar, Hook Guard And Needle Guide

    Hook, needle bar, hook guard and needle guide 2.4.1 Loop stroke The loop stroke is the distance covered by the needle bar from its lower dead centre up to the point where the point of the hook coincides with the middle of the needle. The 1 screw on the hook –...

  • Page 16: Sliding Clutch

    2.4.2 Sliding clutch Caution: Danger of bodily injuries ! The machine must be in the position "Safe motor stop ". Rule and control The sliding clutch should react when the hook is jammed. Adjust the sliding clutch 3 so that it reacts at a torque of 4 Nm. Correction –...

  • Page 17: Needle Bar Height

    2.4.3 Needle bar height Caution: Danger of bodily injuries ! The machine must be in the position "Safe motor stop ". Rule and control In the loop formation position, the hook tip 3 should stand more or less under the middle of the furrow of the needle 2. When the machine is out of the zigzag mode.

  • Page 18: Distance Between The Hook And The Needle

    2.4.4 Distance between the hook and the needle Caution: Danger of bodily injuries ! The machine must be in the position "Safe motor stop ". The distance between the hook and the needle must be checked after inserting a needle that belongs to a different size group (80-110 Nm or 120-140 Nm).

  • Page 19: Position Of The Needle Guide

    2.4.5 Position of the needle guide The needle guide 5 should guide the needle during the sewing process in order to avoid its excessive deflection by the fabric. Otherwise, skipped stitches can occur. The distance between the hook and the needle must be checked after inserting a needle that belongs to a different size group (80-110 Nm or.

  • Page 20: Bobbin Case Lifter

    Bobbin case lifter 2.5.1 General information The thread take-up lever should pass the thread between the bobbin case 4 and its support 3. For ensuring a free thread passage, the bobbin case must be lifted in this moment by the bobbin case lifter. This will ensure the desired seam pattern with the lowest possible thread tension.

  • Page 21: Amount Of The Lifting Gap (Position Of The Finger Travel)

    2.5.3 Amount of the lifting gap (position of the finger travel) Caution: Danger of bodily injuries ! The machine must be in the position "Safe motor stop ". Rule and control The X distance between the lifted bobbin case and its holder should correspond to the size of the thread used.

  • Page 22: Timing The Bobbin Case Lifting

    2.5.4 Timing the bobbin case lifting Caution: Danger of bodily injuries ! The machine must be in the position "Safe motor stop ". Rule and control The bobbin case must be in its lifted position when the thread passes between the bobbin case 3 and its support 4. –...

  • Page 23: Sewing Foot

    Sewing foot 2.6.1 General information The adjustment of the upper and lower sewing foot travel position is described under chapter 6.2.6 of the Operating Instructions. 2.6.2 Timing the sewing foot movement Caution: Danger of bodily injuries ! The machine must be in the position "Safe motor stop ". Rule and control The sewing foot should start moving upwards at the moment of the loop formation.

  • Page 24: Thread Take-Up Spring

    Thread take-up spring Caution: Risk of Injury ! The machine must be in the position "Secured stop of motors". Rule and control Adjust the travel and the tension of the thread take-up spring in a way that at the moment when the spring reaches its lowest position, the eye of the stitching needle is disappearing in the fabric.

  • Page 25: Lifting The Thread Tensioner

    Lifting the thread tensioner The thread tensioner will be lifted during the cutting process or after pressing the button 3 on the supporting plate. Caution: Danger of bodily injuries ! Turn off the main switch. Switch off the machine before adjusting the lifting of the thread tensioner.

  • Page 26: Thread Advancing Device

    Thread advancing device During the cutting process, the thread advancing device 2 will be moved forwards after picking up the loop, and it will be returned during the 2 movement phase of the thread cutting knife The thread advancing device has been timed by the control unit. No change is possible.

  • Page 27: Lubrication

    2.10 Lubrication 19 20 13 12 2.10.1 General information – The wicks used for the lubrication of the respective elements in the machine head should not touch the re-circulation wick. – The plastic cap on the hook impedes the suction of dust and fluff into the hook case by the vacuum pump.

  • Page 28: Mode Of Function

    2.10.2 Mode of function Oil supply from the sump to the sewing head The oil passes from the oil sump to the cavity in the sewing head through the spiral grooves in the hook driving shaft 19 and through the duct 7.

  • Page 29: Adjusting The Hook Lubrication

    2.10.4 Adjusting the hook lubrication Caution: Danger of bodily injuries ! Do not introduce your hands into the area of the moving machine parts. Rule and control The hook should be lubricated safely with the lowest possible oil quantity. (This will also reduce the oil consumption) –...

  • Page 30: Oil Change

    2.10.5 Oil change Caution: Danger of bodily injuries ! Turn off main switch. Switch off the machine before proceeding to the oil change The oil should be changed after the first 500 service hours as follows: – Remove the oil sump cover. –...

  • Page 31: Sewing Arm

    2.11 Sewing arm 2.11.1 General information The switches on the cylinder are actuated by the magnet core on the piston rod when the sewing head is lifted or lowered. The catch 1 serves for locking the sewing head in its upper position when the pneumatic system is depressurised, e.g.

  • Page 32: Speed "Sewing Arm Up And Down

    2.11.3 Speed "Sewing arm up and down " Caution: Danger of bodily injuries ! Do not introduce your hands into the area of the moving machine parts. Rule and control The sewing head should move continuously and regularly. – Select repeatedly the function "Lifting/lowering the sewing head ".

  • Page 33: Thread Cutter

    2.12 Thread cutter 2.12.1 Sequence of functions Pos. 1) Pos. 2a) Pos. 2b) Checking the thread cutting process – When switching on during the display of the Dürkopp Adler Logo press the key "F2". – Press the key "I". The adjustment menu will appear. –...

  • Page 34: Lateral Position Of The Thread Pulling Knife

    2.12.2 Lateral position of the thread pulling knife Rule and control – The thread pulling knife 2 should travel along the bobbin case lug 1 at a safe distance. – The thread pulling knife 2 should not knock against the bobbin case 3.

  • Page 35: Height Of The Thread Pulling Knife

    2.12.3 Height of the thread pulling knife Rule and control The thread pulling knife 1 should be as close to the bobbin as possible when it crosses the bobbin, however without touching the latter. Caution: Danger of bodily injuries ! The machine must be in the position "Safe motor stop ".

  • Page 36: Position Of The Counter-Knife In Respect To The Thread Pulling Knife

    2.12.4 Position of the counter-knife in respect to the thread pulling knife Caution: Danger of bodily injuries ! The machine must be in the position "Safe motor stop ". Rule and control – The counter-knife support 4 should bed as close to the rear casting edge as possible.

  • Page 37: Position Of The Hook Thread Clamp

    2.12.5 Position of the hook thread clamp The purpose of the clamp 1 is to clamp the hook thread during the cutting process, so that it can be safely caught by the needle thread when starting the seam. Caution: Danger of bodily injuries ! Turn off main switch.

  • Page 38: Position Of The Control Cam

    2.12.6 Position of the control cam The control cam 4 determines the sequence of movements of the thread pulling knife. Caution: Danger of bodily injuries ! Turn off main switch. Switch off the machine before adjusting the control cam. Rule and control In the upper position of the thread take-up lever, the hole 5 in the control cam 4 should be located on the connecting line A between the shaft 7 and the roller 9 of the lever 3.

  • Page 39: Position Of The Roller Lever In Respect To The Control Cam

    2.12.8 Position of the roller lever in respect to the control cam The control cam 6 should not touch the roller lever 4 during the sewing process. Caution: Danger of bodily injuries ! Turn off main switch. Switch off the machine before adjusting the control cam. Rule and control The distance of the roller lever 4 to the topmost point of the control cam 5 should amount to 0.1 mm when the magnet armature 1 is fully...
  • Page 40 2.12.9 1 and 2 position of the thread cutting knife Caution: Danger of bodily injuries ! Do not introduce your hands into the area of the moving machine parts. Rule and control 1st position The thread cutter will be activated in this position after the "seam end" signal.

  • Page 41: Machine Head (Class 806-121)

    Machine head (class 806-121) Adjusting aids 3.1.1 Gauge set The setting gauges, specified hereinafter, enable a precise setting and checking of the machine head. Position Setting gauge Ref. No.. Setting pin 9301 022608 Stopping the sewing machine in A - F position Gauge 0804 400290 Distance gauge (Plate / Arm)

  • Page 42: Description And Adjustment Of The Integrated Adjustment Disk

    3.1.2 Description and adjustment of the integrated setting disk By means of the locking pin 1 and the integrated setting disk 2, located on the toothed belt pulley, the machine can be locked in any setting position. The setting disk is provided for this purpose with 6 incisions, marked on the handwheel by the letters A, B, C, D, E and F.

  • Page 43: Position Of The Integrated Adjustment Disk In Respect To The Arm Shaft

    3.1.3 Position of the integrated setting disk in respect to the arm shaft ATTENTION ! All settings made by the setting disk are only correct if the settings have been made as described under the rule. Following a displacement of the arm shaft, check and, if necessary, correct all the following settings.

  • Page 44: Sewing Foot Height / Lower Stroke Position

    Sewing foot height / lower stroke position Caution: Danger of bodily injuries ! The machine must be in the "Safe motor stop" position. Rule and control – Lower the sewing head by the function "Lifting/lowering the sewing head". – Press the key "O". "Safe motor stop"...

  • Page 45: Needle Thread Tension Release

    Needle thread tension release Rule and control By the pressure against the axle 2, the tensioner will be opened about 1 mm. Caution: Danger of bodily injuries ! Turn off main switch. Switch of the sewing machine before correcting the release of the needle thread tensioner.

  • Page 46: Thread Tensioning Spring

    Thread pulling spring Rule and control The thread pulling spring 1 should hold the needle thread tensioned at least until the tip of the needle stitches into the fabric. Caution: Danger of bodily injuries ! Turn off main switch. Switch off the sewing machine before correcting the thread pulling spring.

  • Page 47: Bobbin Winder

    Bobbin winder 3.5.1 Adjusting the bobbin winder Rule and control The bobbin winder should stop automatically when the thread wound on the bobbin is about 0.5 mm from the bobbin rim. The thread must be wound cylindrically. Caution: Danger of bodily injuries ! Turn off main switch.

  • Page 48: Replacing Friction Ring

    3.5.3 Exchanging the friction ring Caution: Danger of bodily injuries ! Turn off main switch. Switch off the sewing machine before correcting the bobbin winder. – Remove the bobbin winder cover. – Exchange the friction ring. – Fit the bobbin winder cover. 3.5.4 Resetting the bobbin winder wheel Caution: Danger of bodily injuries !

  • Page 49: Hook Adjustments

    Hook adjustments 3.6.1 Loop stroke and distance between the hook tip and the needle 0,1 mm Rule and control The loop stroke is the distance covered by the needle bar from its lower dead centre up to the tip where the tip of the hook coincides with the middle of the needle.

  • Page 50: Hook Drive Housing

    3.6.2 Hook drive housing Caution: Danger of bodily injuries ! Turn off main switch. Switch off the sewing machine before correcting the hook drive housing. Rule and control The hook drive housing 6 has been aligned in the factory. It may be readjusted only in exceptional cases ! With a correct adjustment of the hook drive housing, the distance between the hook and the setting ring must amount to 0,4 mm (see chapter 7.1).

  • Page 51: Bobbin Case Support

    3.6.3 Bobbin case support +0,1 Rule and control The bobbin case support has been set in the factory. Following a change of the support, it may be necessary to readjust the new support. The spring wire 1 should rest on the bobbin case bottom flush and without any gap.

  • Page 52: Adjusting The Throat Plate

    3.6.4 Adjusting the throat plate General For cleaning the throat plate, it can be removed after loosening the screws 1 and 2, without causing any adjustment changes. The adjusting washers under the screws 3 and 4 will again position the throat plate.

  • Page 53: Adjusting The Hook Guard

    3.6.5 Adjusting the hook guard Caution: Danger of bodily injuries ! The machine must be in the "Safe motor stop" position. Rule and control Adjust the hook guard so that it is in contact with the needle, but without deflecting the latter. –...

  • Page 54: Thread Cutter

    Thread cutter The control cam 4 determines the movement of the thread cutter and the time of its action. Consequently, the time of action corresponds to the sequence of movements of the stitch-forming elements. The thread cutter is switched by electromagnetic means. 3.7.1 Control cam for timing the knife movement Rule and control...

  • Page 55: Position Of The Stationary Knife

    3.7.2 Position of the stationary knife Rule and control The stationary knife 3, seen in the arrow direction, must be in contact with the screw 1 (see the sketch). Reground knives must be adjusted according to chapter 3.7.3 ! Caution: Danger of bodily injuries ! Turn off main switch.

  • Page 56: Regrinding The Stationary Knife

    3.7.3 Regrinding the stationary knife 15° Rule and control The cutting angle of the stationary knife 5 amounts to 15° (see the sketch). For regrinding it is absolutely necessary to use a fine grain stone. Caution: Danger of bodily injuries ! Turn off main switch.

  • Page 57: Adjustment Sheet

    3.7.4 Adjusting sheet Rule and control Use for the big hook the adjusting sheet 2. The adjusting sheet 2, seen in the arrow direction, must rest against the screw 3 (see the sketch). Radially, the distance between the adjusting sheet 2 and the hook-shaped knife 1 should amount to 0.3 mm.

  • Page 58: Hook-Knife

    3.7.5 Hook-shaped knife Rule and control The hook-shaped knife 2, seen in the arrow direction, must rest against the two screws 1. In neutral position of the hook-shaped knife, its tip 6 and the cutting edge 7 must be flush with the stationary knife 5. During the movement of the knife, the tip 6 of the hook-shaped knife must stand, coincident, in the adjusting sheet 4 under the tip of the triangle 3.

  • Page 59: Cutting Pressure

    3.7.6 Cutting pressure Rule and control The thread cutting pressure must be as low as possible. A low cutting pressure will reduce the wear ! Two of the thickest threads used must be cut safely at the same time Caution: Danger of bodily injuries ! Turn off main switch.

  • Page 60: Replacing Right Hand Arm Shaft Bearing

    Replacing right arm shaft bearing Rule and control The right arm shaft bearing must be replaced when the operation of the arm shaft is sluggish. Caution: Danger of bodily injuries ! Turn off main switch. Switch off the sewing machine before replacing the arm shaft bearing. ATTENTION ! Do not use any extraction tool ! When removing or installing the right arm shaft bearing no axial...

  • Page 61: Lubrication

    Lubrication 3.9.1 General information The oil passes from the oil supply container 3 to the oil sump 2. This oil is used for lubricating the lubrication points in the arm and head area. The oil projected by the crank drive passes via the wick 1 to the hook oil container 5.

  • Page 62: Checking Oil Level And Oil Supply

    3.9.2 Checking oil level and oil supply Rule and control After long stops, the major part of the oil is in the lower oil container. Therefore, the oil level should be checked after about 20 sewing cycles. – Check oil level in oil container 1. The oil level must stand between the marks MIN and MAX.
  • Page 63 Correction – Fill the oil container 1 up to the mark "MAX". - For the hook lubrication see chapter 3.9.3 - For replenishing the oil containers use exclusively the ESSO SP-NK 10 oil or any other oil with following specification: Viscosity at 40°...

  • Page 64: Hook Lubrication

    3.9.3 Hook lubrication Caution: Danger of bodily injuries ! When the machine is switched on, be very careful when checking the hook lubrication. Turn off main switch. Switch off the sewing machine before correcting the hook lubrication. Rule and control The oil quantity required for the hook lubrication is adjustable and depends on the stress of the machine.

  • Page 65: Adjusting The Remaining Thread Monitor

    3.10 Adjusting the remaining thread monitor Rule and control Adjust the remaining thread monitor so that the end of the hook thread is recognised. – Select the function "Adjusting the remaining thread monitor". – Insert empty bobbin. – The symbol should not be crossed when the reflecting surface 1 stands in front of the light barrier.

  • Page 66: Sewing Arm Position

    3.11 Sewing arm position 3.11.1 Lower position of the sewing arm Rule and control When the arm is in its lowered position, the square distance gauge 4 (Ref. no.: 0804 400290) should fit exactly between the throat plate and the bottom of the sewing arm. –...

  • Page 67: Damping The Cylinder In Its End Position

    3.11.3 Damping the cylinder in its end position General The speed of the sewing head is reduced about 10 mm before the end position, so that the sewing head is braked softly. Rule and control – Select repeatedly the function "Lifting/lowering the sewing head".

  • Page 68: Folding Device

    Folding device Outer frame 4.1.1 General information The outer frame supports following functional elements: – Lateral slide – Front slide – Corner slide – Corner slide (in) – Inner frame 4.1.2 "Folding position" of the outer frame Caution: Danger of bodily injuries ! Do not introduce your hands into the area of the moving machine parts.

  • Page 69: Timing The Action Of The Switches

    4.1.3 Timing the operation of the switches Rule and control The switches S3, S6 and S8 should be operated short before the end position of the outer frame. – When switching on, hold the key "F3" pressed down. – Select the function "Checking the input elements ". –...

  • Page 70: Damping The Cylinder In Its End Position

    4.1.4 Damping the cylinder in its end position The damping of the pistonrod-free cylinder "Outer frame forwards and backwards " begins already 20 mm from the end positions. Caution: Danger of bodily injuries ! Do not introduce your hands into the area of the moving machine parts. Rule and control –...

  • Page 71: Inner Frame

    Inner frame 4.2.1 General information – The inner frame 4 is linked to its supports in a springy way at 3 points. – The vacuum field under the inner frame 4 sucks the middle slide, so that it can be pulled up into the "Folding position". 4.2.2 Adjustment range of the front setting wheel The setting wheel 5 permits to determine "the folding position"...

  • Page 72: Middle Slide

    Middle slide 4.3.1 General information – The middle slide 1 determines the outer contour of the pocket to be set. – The lower sheet of the middle slide 1 should fix the folded edges, when the lateral, front and corner slides are again moving into their initial position.

  • Page 73: Adjustment Range Of The Rear Setting Wheel

    4.3.2 Adjustment range of the rear setting wheel The position of the setting wheel 1 determines the "Folding position" of the middle slide in its rear section. The "Folding position" in the "front" section depends on the position of the setting wheel 4. Caution: Danger of bodily injuries ! Do not introduce your hands into the area of the moving machine parts.

  • Page 74: Limiting The Movement" Middle Slide Up

    4.3.3 Limiting the movement "Middle slide up" Caution: Danger of bodily injuries ! Do not introduce your hands into the area of the moving machine parts. Rule and control The upwards movement of the middle slide must be limited by the levers 2 on the outer frame and not by the cylinder "Middle slide up".

  • Page 75: Adjustment Position" Of The Middle Slide

    4.3.4 "Adjustment position" of the middle slide After positioning the cut pocket fabric on the middle slide, the latter can be lowered by the key 1, for adjusting the basic part "according to the pattern". Caution: Danger of bodily injuries ! Do not introduce your hands into the area of the moving machine parts.

  • Page 76: Speed "Middle Slide Forwards, Down, Up

    4.3.5 Speed "Middle slide forwards, downwards and upwards " Caution: Danger of bodily injuries ! Do not introduce your hands into the area of the moving machine parts. Rule and control The middle slide should move continuously and regularly. – Watch the advance movement during the folding process.

  • Page 77: Timing The Operation Of The Switches

    4.3.6 Timing the operation of the switches Caution: Danger of bodily injuries ! Do not introduce your hands into the area of the moving machine parts. Rule and control The switches should release signals at the following moments: Operation of the signal when the middle slide is about 80 mm from the rear end position Release of the switch in the front position of the Middle slide...

  • Page 78: Lateral Slide, Front Slide And Corner Slide

    Lateral slide. front slide and corner slide 4.4.1 General information These slides are folding the cut pocket fabric around the middle slide when the latter has been taken into the folding position by the inner frame. 4.4.2 Front position of the slide Caution: Danger of bodily injuries ! Do not introduce your hands into the area of the moving machine parts.

  • Page 79: Corner Slide

    Corner slide 4.5.1 Position of the "fold edge" of the lateral slide Caution: Danger of bodily injuries ! Do not introduce your hands into the area of the moving machine parts. Rule and control Following the "corner introduction" the position of the cut part should be as shown in the illustration at the right top.

  • Page 80: General Information

    4.5.2 General information – The purpose of the corner slide 6 is to place the fabric under the 30°-edge of the lateral slide 5, in order to avoid any fabric projection in the pocket opening area. – In case of corner introduction slides for the class 806-111 attention must be paid to the prescribed swivel position.

  • Page 81: Height Of The Corner Introduction Slide

    4.5.4 Height of the corner introduction slide Caution: Danger of bodily injuries ! Do not introduce your hands into the area of the moving machine parts. Rule and control The distance between the entered corner introduction slide 2 and the lateral slide sheet 3 should correspond to a middle fabric thickness.

  • Page 82: Position Of The Two Setting Wheels

    Position of the two setting wheels The position of the rear setting wheel 1 determines the "Folding position" of the middle slide in its "rear section. The position of the setting wheel required for the respective fabric type is indicated, as far as it has been determined, on the sticker of the transfer plate.

  • Page 83: General Information

    Plug General information – The stacker version with a roller enables stacking of parts the lower edge of which is at least 310 mm from the seam end. Normally, this requirement for all trousers and shirt parts. The stacker version with an additional roller enables stacking of parts the lower edge of which is distanced 130 and 310 mm from the seam end.

  • Page 84: Turning The Rest Of The Stacker

    Turning the rest o the stacker The rest of the stacker can be turned for enabling stacking of normal parts and of parts with a button stay. – Loosen the hexagon screws 1 and 2 by a hexagonal spanner (Spanner opening 6 mm). –...

  • Page 85: Lateral Position Of The Roller-Out And Of The Stacker

    Lateral position of the roller and of the stacker 5.3.1 Lateral position of the roller Rule and control – For shirts with button stay: The left roller should stand above the button stay. – For all other parts: The rollers should be centered in compliance with the basic parts. –...

  • Page 86: Position Of The Opened Inner Shackle

    Position of the opened inner shackle Caution: Danger of bodily injuries ! The machine must be in the "Safe motor stop" position. Rule and control The opened inner shackle 1 should be, in horizontal direction, about 10 mm from the fabric rest. –...

  • Page 87: Sensitivity Of The Light Barrier

    Sensitivity of the light barrier The light barrier emits the signal "Part rolled out " , so that the stacking process can be continued. Caution: Danger of bodily injuries ! Do not introduce your hands into the area of the moving machine parts. Rule and control –...

  • Page 88: Speed Of The Outer Shackle, Of The Inner Shackle And Of The Deposit Rest

    Speed of outer shackle, inner shackle and rest Caution: Danger of bodily injuries ! Do not introduce your hands into the area of the moving machine parts. Rule and control – All elements should move continuously and regularly. – The outer shackle 2 should be fully opened when the part is ejected.

  • Page 89: Speed Of "Ejection Rollers Up And Down

    Speed of the "Ejection rollers up and down " Caution: Danger of bodily injuries ! Do not introduce your hands into the area of the moving machine parts. Rule and control The rollers of the roller-out 6 should move continuously and regularly. –...

  • Page 90: Adjustment Options

    Adjustment options All adjustments described in this section are made before delivering the machine. Should the adjustments get lost, they must be restored manually. Following parameters are set with this menu: – Machine class – Remaining thread monitor available – End position switch of the transfer carriage available –...

  • Page 91: Continuous Operation

    Continuous operation By means of the "Continuous operation" function the 806 can be switched over to the continuous operation mode for testing the machine. ATTENTION ! This function is intended exclusively for the internal use by DÜRKOPP ADLER AG for testing the machine prior to the delivery. In no case should this function be used outside.

  • Page 92: Checking The Roll-Out

    Checking the roll-out The roll-out menu can be selected by the function "Checking roll-out". Following symbols are used for setting the roll-out speed. Each symbol can be switched on and off individually. Each symbol has a different value, permitting to set 15 rotating speeds. The figure under the symbol indicates the value of the symbol.

  • Page 93: Transfer Carriages General Information

    Transfer carriages General information The transfer carriages , moved by 2 motors in X and Y direction, have following duties: – Transporting the material by means of the transfer plate from the folding station to the sewing station. – Moving the material during the sewing process according to the seam outer contour Following static traction forces of the X and Y carriage can be used for trouble shooting.

  • Page 94: Setting The Reference Point

    Setting the reference point Rule and control – Turn on main switch. The control will be initialised. The display will show briefly the DÜRKOPP-ADLER-Logo. – During the display of the logo press the key "F2". – Press the key "I". The display will present the adjustment menu of the 806 after the basic adjustment run.

  • Page 95: Setting The Limit Switches S45 And S59

    Setting the limit switches S45 and S59 Note: If the limit switches have been installed, they must be activated by the function "Limit switches available " (see chapter 6.4). 7.4.1 x-axis Rule and control The limit switch (S45) for the X-axis limits the maximum travel to the left.

  • Page 96: Y-Axis

    7.4.2 Y-Axis Rule and control The limit switch (S59) for the Y-axis limits the maximum sewing area in respect to the pocket top edge. About 2 mm from the mechanical stop the drives will be stopped in case of an automatic mode of operation. –...

  • Page 97: Position Balance

    Position balance 7.5.1 General The position of the transfer carriage must be balanced – when installing the sewing unit. – when changing the sewing station . – when changing the belt or rectifying the belt tension. – when proceeding to a new setting of the reference point. Note: The sticker on the machine shows the co-ordinates of the positions existing when delivering the machine.

  • Page 98: Balancing The Positions

    7.5.2 Balancing the positions Preparing the transfer plate – By means of the reflecting foil, cover the no. 1 of the coding field by a circle, having a diameter of about 5 mm. – Insert this transfer plate. Position balance for reading-in the coding –...
  • Page 99 Checking the position in respect to the lower sewing position – The transfer carriage travels to the lower sewing position. – Lower the transfer plate by the function "Lowering/lifting the transfer plate". – Lower the sewing head by the function "Lowering/lifting the sewing head".

  • Page 100: Multitest System

    Multitest System The checking programmes of the Multitest Systems enable a quick examination of the input and output systems. No additional measuring instruments are required. – When switching on the 806 hold the key "F3" depressed. The message will pass to the screen of the Multitest system. –...

  • Page 101: Testing The Working Memory

    Testing the working memory The programme tests the working memory (RAM) of the micro-computer. – Select the function "Testing working memory ". The display will show the test result. Display Explanation RAM OK Working memory operates perfectly RAM-Error Error in the working memory –...

  • Page 102: Checking Input Elements

    Checking input elements The programme serves for checking the input elements. – Select the function "Checking input elements ". – Operate the input element to be checked. – The display shows the circuit diagram code and the circuit state of the modified input element (e.g.

  • Page 103: Selecting Output Elements

    Selecting output elements The programme serves for checking the function of the output elements. Caution: Danger of bodily injuries ! Do not introduce your hands into the running machine when checking the function of the output elements. – Select the function "Checking output elements ". –...

  • Page 104: Checking Stepping Motors

    Output Function element Advance roller in lower position Advance roller in upper position Blowing Ejection roller in lower position Ejection roller in upper position 8.7 Checking stepping motors The programme checks the functions of the stepping motors This programme shows the programme version, the check sums and the state of the individual stepping motor controls.

  • Page 105: Terminal Self-Test

    Terminal Self-test Selftest Keyboard EPROM Interface RAM-Card Display List The service staff is using the Terminal-Selftest for checking the single components of the control terminal. Note: The RAM-Test and the EPROM-Test do not check in this menu the RAMs and the EPROMs, existing on the control circuit boards of the 806.
  • Page 106 – Display-Test The Display-Test shows the available "Character Set" and the" Graphic" of the display. After pressing the function key F2 the display will automatically pass over to the main screen of the Terminal-Selftest (see the illustration). – Main screen A complete test report can be fetched from the main screen by pressing the function key F2.

  • Page 107: Start Messages Start Screen

    Start messages 10.1 Start screen 12 Mhz 806-XXX $Date: dd.mm.yy hh:mm $ $Revision: nn $ Axx BED N.SE $Date: dd.mm.yy hh:mm $ $Revision: nn $ Axx STD N.SE When starting the 806, the start screen will present the DÜRKOPP ADLER Logo. Following details will be displayed : –...

  • Page 108: Control Error Messages

    Error messages 11.1 Control error messages Error number Explanation Remedy Undervoltage Stablize power supply 101 - 199 Processor error TRANSFER STOP Safety switch of the transfer plate has been see chapter 4.2 of the triggered Operating Instructions EMERGENCY STOP Emergency switch has been triggered see chapter 4.2 of the Operating Instructions The basic adjustments of the 806 have been lost...
  • Page 109 Error number Explanation Remedy 10022 Reading-in the coding cannot be interrupted Do not stop the machine during the (Position loss). reference run. 10034, 10044, 10064 Hook flap opened. Close hook flap. 10105 No reference stop possible. Do not switch on the Safe Stop when carrying out the function.
  • Page 110 Error number Explanation Remedy 12082 Right route. Cycle control defective. Suppress stepping motor controller Suppress EMV cycle error. error or the configuration of the stepping motor controller bridges is wrong. 12162 Motors already running. Suppress stepping motor controller error or software error. 14011 Timeout, middle slide not in lower position.
  • Page 111 Error number Explanation Remedy 18056 Reference run not properly performed. Carryout reference run once again and readjust the switch, if necessary. (see chapter 7.3) 20017 x-axis end position exceeded. Adjust X-Axis ednd position (see chapter 7.4.1). 20027 Y-Axis end position exceeded. Proceed to a new adjustment of the Y-axis end position (see chapter 7.4.2).

  • Page 112: Pneumatic Conditioning Unit

    Pneumatic conditioning unit 12.1 Air filter and water separator This unit separates soil particles and water, for avoiding obstructions and rust formation in the pneumatic system. The draining of the plastic container takes place automatically by a swimmer valve as soon as a certain water level is reached.

  • Page 113: Monthly Maintenance Lubrication

    Monthly maintenance 13.1 Lubrication Following assemblies of the transfer carriage must be lubricated monthly : – Spherical bush 2 of the torque shaft – Carriage of linear rails – Spherical heads Caution: Danger of bodily injuries ! Turn off main switch. Switch off the machine before lubricating the lubrication points of the transfer carriage.

  • Page 114: Ventilation Grid Of The Control Unit

    13.2 Ventilation grid and control Caution: danger of bodily injuries ! Switch off the machine before cleaning the ventilation grid and the control unit. – Turn off main switch. – Remove cover 1. – Remove fan cover 3. – Remove the sieve and clean it by the compressed air gun. –...

  • Page 115: Maintenance

    Maintenance Caution: Danger of bodily injuries ! Turn off main switch. Switch off the machine before proceeding to the maintenance of the machine. Daily and weekly maintenance work to be carried out by machine operators (cleaning and lubrication is described under Part 1 of the Operating Instructions.

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