Duerkopp Adler 650-16 Service Instructions Manual
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Duerkopp Adler 650-16 Service Instructions Manual

Duerkopp Adler 650-16 Service Instructions Manual

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  • Page 1 650-16 Service instructions...
  • Page 2 All rights reserved. Property of Dürkopp Adler AG and copyright protected. Any use of this content, or part of it, is prohibited without prior written permission of Dürkopp Adler AG. Copyright © Dürkopp Adler AG - 2012...

  • Page 3: Table Of Contents

    Toothed belt for hook drive ..................33 Replacing and adjusting the top transport belts ..........35 12.1 Replacing the top transport belts ................35 12.2 Adjusting the top transport belts................37 Service Instructions 650-16 Version 00.0 - Last Updated 09/2012...
  • Page 4 Checking the key functionality at the control panel ..........74 Maintenance work ....................75 19.1 Lubrication........................ 75 19.2 Cleaning ........................76 Appendix......................... 77 20.1 Software error messages ..................77 20.2 Circuit diagram ......................81 Service Instructions 650-16 Version 00.0 - Last Updated 09/2012...

  • Page 5: General

    1.1 Scope of this Guide This guide describes settings and maintenance work on the Custom Ma- chine 650-16 for sewing in sleeves. It applies to all subclasses. Intended use and installation are described in the  Operating instructions. 1.2 Declaration of conformity The machine conforms with the European regulations stated in the decla- ration of conformity or incorporation.

  • Page 6: Safety Instructions

    Only qualified and trained staff are allowed to perform servicing, mainte- nance and repairs. Any person maintaining or adjusting the machine must Service Instructions 650-16 Version 00.0 - Last Updated 09/2012...

  • Page 7: Marking Of Safety Instructions

    Risk of damage. In case of dangers for persons, these symbols indicate the type of danger: General danger Danger due to electric shock Danger due to pointed objects Danger due to crushing Service Instructions 650-16 Version 00.0 - Last Updated 09/2012...
  • Page 8 Attention Type and source of danger Consequences in case of failure to observe Measures for preventing the danger Danger notice where failure to observe can lead to damage to proper- Service Instructions 650-16 Version 00.0 - Last Updated 09/2012...

  • Page 9: Environmental Protection Notes

    Example for marking of environmental protection notes in the text Environmental Type and source of danger Consequences in case of failure to observe Measures for preventing the danger Danger notice where failure to observe can lead to damage to property. Service Instructions 650-16 Version 00.0 - Last Updated 09/2012...

  • Page 10: Work Principles

    Shows you what to pay attention to in the current step. Information Provides additional information. Order States which work you must perform before or after the setting. References  This is followed by a reference to another part of the text. Service Instructions 650-16 Version 00.0 - Last Updated 09/2012...

  • Page 11: Order Of Settings

    The bolts either stay in the housing or in the cover. In the text, these bolts are marked with the supplement (safety cover). Service Instructions 650-16 Version 00.0 - Last Updated 09/2012...

  • Page 12: Removing Covers

    Returning the machine upper part to upright position 1. Replace the tray (2). 2. Tighten all 5 bolts (3) (Safety cover  p. 9). 3. Prop up the machine upper part (1). Service Instructions 650-16 Version 00.0 - Last Updated 09/2012...

  • Page 13: Removing And Replacing The Top Cover

    2. Remove the rear arm cover (2). Replacing the rear arm cover 1. Replace the rear arm cover (2). 2. Tighten all 5 bolts (1) (Safety cover  p. 9) on the rear arm cover. Service Instructions 650-16 Version 00.0 - Last Updated 09/2012...

  • Page 14: Removing And Replacing The Fabric Base And Column Cover

    Replacing the fabric base and column cover 1. Replace the column cover (2) from the top left. 2. Replace the fabric base (3) from the top left. 3. Tighten both bolts (1) (Safety cover  p. 9). Service Instructions 650-16 Version 00.0 - Last Updated 09/2012...

  • Page 15: Removing And Replacing The Needle Plate

    (2) fits into the recess (6) on the hook (7). 3. Secure the guide piece (3) with bolts (4). 4. Replacing the fabric base and column cover.( Chap. 4.5.4, p. 12) Service Instructions 650-16 Version 00.0 - Last Updated 09/2012...

  • Page 16: Surfaces On Shafts

    (4), the corresponding groove on the arm shaft crank (2) is located below the opening for the locking pin (1). Service Instructions 650-16 Version 00.0 - Last Updated 09/2012...
  • Page 17 The numbers on the handwheel provide rough orientation. To hit the groove precisely, you might need to turn the handwheel slightly. Releasing the lock 1. Remove the locking pin (3) 2. Insert the plug (1) into the locking opening (2) Service Instructions 650-16 Version 00.0 - Last Updated 09/2012...

  • Page 18: Adjusting The Lightbeam Sensor Disk

    • Incorrect needle position, needle jams in hole • Incorrect transport times • Incorrect thread trimming • Poor sewing results Cover • Access to the underside of the machine ( Chap. 4.5.1, p. 10) Service Instructions 650-16 Version 00.0 - Last Updated 09/2012...
  • Page 19 Important: The sensor disk must be aligned laterally so that the 180° disk (3) does not touch the lightbeam housing. 4. Tighten both grub screws (1) without changing the position of the sensor disk. 5. Release the lock ( p. 15). Service Instructions 650-16 Version 00.0 - Last Updated 09/2012...

  • Page 20: Adjusting The Hook And The Needle Bar

    The looper stroke is the length of the stroke from bottom dead centre of the needle bar to the height at which the hook is in looper stroke position. The looper stroke on the 650-16 is 1.8 mm. Figure 10: Loop stroke position...

  • Page 21: Adjusting The Looping Stroke Position And Hook Spacing

    ( Chap. 6.2 Adjusting the needle bar height, p. 20). 6. After finally aligning the looper stroke position, hook clearance and nee- dle bar: release the lock ( p. 15). Service Instructions 650-16 Version 00.0 - Last Updated 09/2012...

  • Page 22: Adjusting The Needle Bar Height

    ( Chap. 6.1 Adjusting the looping stroke position and hook spacing, p. 19). 5. After finally aligning the looper stroke position, hook clearance and nee- dle bar: release the lock ( p. 15). Service Instructions 650-16 Version 00.0 - Last Updated 09/2012...

  • Page 23: Adjusting The Thread Passage On The Centre Part Mount

    3. Push or pull out the centre part holder (3) so that the thread can pass freely between the centre part holder (3) and the hook recess (5) without the gap becoming unnecessarily large. 4. Tighten the grub screw (1). Service Instructions 650-16 Version 00.0 - Last Updated 09/2012...

  • Page 24: Adjusting The Needle Plate Position

    4. Turn the column head (1) and displace laterally so that the needle passes precisely through the hole (4) in the needle plate (3). 5. Tighten both fastenings screws (2) without changing the position of the column head (1). Service Instructions 650-16 Version 00.0 - Last Updated 09/2012...

  • Page 25: Adjusting The Thread Trimmer

    (2) - Roller Malfunctions in case of incorrect settings. • Damage to the needle • Threads are not cut Cover • Access to the underside of the machine( Chap. 4.5.1, p. 10) Service Instructions 650-16 Version 00.0 - Last Updated 09/2012...
  • Page 26 (4) latches precisely in the small recess (1). 4. Tighten both control curve grub screws (5) without changing the position of the control curve. 5. Release the lock ( p. 15). Service Instructions 650-16 Version 00.0 - Last Updated 09/2012...

  • Page 27: Distance Between Control Curve And Roller

    Malfunctions in case of excessive gap • Thread puller blade and counter-blade can jam Cover • Access to the underside of the machine( Chap. 4.5.1, p. 10) Service Instructions 650-16 Version 00.0 - Last Updated 09/2012...
  • Page 28 Important: The anchor of the thread trimmer solenoid must be fully ex- tended. 4. Tighten the fastening screw (2) on the thread trimmer lever (3) through the screw opening (6) in the housing without changing the lever position. Service Instructions 650-16 Version 00.0 - Last Updated 09/2012...

  • Page 29: Replacing And Adjusting Thread Puller Blades

    (1) downward while doing so. 4. Insert a new thread puller blade 5. Push the thread puller blade (3) up to the front stop against the fastening screws (2) 6. Tighten the fastening screws (2). Service Instructions 650-16 Version 00.0 - Last Updated 09/2012...

  • Page 30: Replacing The Counter-Blade

    (3) - Counter-blade screw Adjusting steps 1. Fully unscrew the counter-blade screw (3). 2. Pull out the old counter-blade to the front. 3. Insert a new counter-blade 4. Tighten the counter-blade screw (3). Service Instructions 650-16 Version 00.0 - Last Updated 09/2012...

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

    (1) and counter-blade (2) touch but do not jam. 4. Tighten the counter-blade screw (3). 5. Perform a cutting test and repeat steps 2 to 4 if needed. Service Instructions 650-16 Version 00.0 - Last Updated 09/2012...

  • Page 32: Adjusting The Thread Puller Blade Stroke

    4. Perform a cutting test and repeat steps 1 to 3 if needed. If the threads are cut too long: push the thread puller blade further back. If the threads are not cut, pull the thread puller blade toward the front. Service Instructions 650-16 Version 00.0 - Last Updated 09/2012...

  • Page 33: Adjusting The Central Foot

    1. Removing the needle ( Operating instructions Chap. 8.7). 2. Release the screw (1). 3. Push the central foot (2) up or down so that the height matches the fabric thickness. 4. Tighten the screw (1) Service Instructions 650-16 Version 00.0 - Last Updated 09/2012...

  • Page 34: Adjusting The Toothed Belt

    • Adjusting the lightbeam sensor disk ( Chap. 5, p. 16) • Hook position ( Chap. 6.1 Adjusting the looping stroke position and hook spacing, p. 19) Service Instructions 650-16 Version 00.0 - Last Updated 09/2012...

  • Page 35: Toothed Belt For Hook Drive

    Important: Do not loosen screw (3). If you loosen screw (3), you must readjust the hook ( Chap. 6.1 Adjusting the looping stroke position and hook spacing, p. 19). 2. Slightly raise the cover (1) and pull off to the right. Service Instructions 650-16 Version 00.0 - Last Updated 09/2012...
  • Page 36 After replacing a toothed belt or releasing the large pulley, you must al- ways check the following settings: • Hook position( Chap. 6.1 Adjusting the looping stroke position and hook spacing, p. 19) Service Instructions 650-16 Version 00.0 - Last Updated 09/2012...

  • Page 37: Replacing And Adjusting The Top Transport Belts

    7. Push the left sewing foot up and the right sewing foot down. 8. Remove the right transport belt from the sewing foot. 9. Take the right transport belt off the pulley (6) and remove from the guide (5). Service Instructions 650-16 Version 00.0 - Last Updated 09/2012...
  • Page 38 11.Turn the pulley (6) slowly so that the belt lines up. Order After replacing the top transport belts you must adjust the central foot ( Chap. 10 Adjusting the central foot, p. 31). Service Instructions 650-16 Version 00.0 - Last Updated 09/2012...

  • Page 39: Adjusting The Top Transport Belts

    • Transport problems and wrinkling in case of excessive tension • Incomplete lowering of the feet • Increased wear on belts and feet Cover • Rear arm cover( Chap. 4.5.3, p. 11) Service Instructions 650-16 Version 00.0 - Last Updated 09/2012...
  • Page 40 2. Push the run-off protection (4) up or down until the clearance to the top right transport belt (3) is 0.2 – 0.3 mm. 3. Tighten both screws (5) on the run-off protection (4). Service Instructions 650-16 Version 00.0 - Last Updated 09/2012...

  • Page 41: Replacing And Adjusting The Bottom Transport Belts

    3. Pull the transport belts (2) up through the cut-out in the base plate (3). 4. Pull both transport belts one after another off the sprockets on the needle plate (1). Service Instructions 650-16 Version 00.0 - Last Updated 09/2012...
  • Page 42 2. Route the transport belt down through the base plate cut-out (3). 3. Pull the transport belt over the lower sprocket (5). 4. Repeat steps 1 – 3 for the left transport belt. Service Instructions 650-16 Version 00.0 - Last Updated 09/2012...

  • Page 43: Adjusting The Bottom Transport Belts

    2. Move the mounting brackets (2) with the wheels and transport belts up or down: • Increase tension: push the unit down. • Reduce tension: push the unit up. 3. Tighten the mounting bracket (2) with the fastening screws (1). Service Instructions 650-16 Version 00.0 - Last Updated 09/2012...

  • Page 44: Replacing Sprockets

    1. Push on the rear sprocket (3) from the left 2. Tighten all 3 guide screws (2). 3. Push on the front sprocket (1) from the left 4. Fitting the lower transport belts ( Chap. 13.1, p. 39) Service Instructions 650-16 Version 00.0 - Last Updated 09/2012...

  • Page 45: Checking The Sewing Foot Lifting Gear

    • After checking for mechanical problems, you must recalibrate the sew- ing feet in the software ( Section Subitem Foot Calib, p. 69). Cover • Rear arm cover ( Chap. 4.5.3, p. 11) • Top cover ( Chap. 4.5.2, p. 11) Service Instructions 650-16 Version 00.0 - Last Updated 09/2012...
  • Page 46 8. Remove the gearbox. Check the gearbox: 1. Move all joints on the gearbox: All rotation and bearing points must move freely and must be free of play. Service Instructions 650-16 Version 00.0 - Last Updated 09/2012...
  • Page 47 8. Tighten the clamping blocks (3) with the screws (4). Access is via the machine head. Order After mechanical work on the sewing foot lifting gear, always calibrate the sewing feet with the software ( Subitem Foot Calib, p. 69). Service Instructions 650-16 Version 00.0 - Last Updated 09/2012...

  • Page 48: Electrical Thread Tensioner

    4. Pull out the blade terminals (4) from the transparent plugs (3) on the Only when fitting a new thread ten- rear above the step motors. sioner 5. Carefully pull out the cable to the front. Service Instructions 650-16 Version 00.0 - Last Updated 09/2012...
  • Page 49 ( Section Subitem Thread Calib, p. 69) Adjusting the tension for thread trimming in the software Cutting tension The thread tension for thread trimming is set in the software ( Section Submenu Thread Trim, p. 60). Service Instructions 650-16 Version 00.0 - Last Updated 09/2012...

  • Page 50: Replacing The Thread Tensioning Spring

    6. Remove the thread tensioning spring (7) from the cylinder. To do so, pull out the spring thread from the inside with a screwdriver. 7. Pull the open end of the spring through the slot (6). Service Instructions 650-16 Version 00.0 - Last Updated 09/2012...
  • Page 51 Figure 39: Tensioning washer order washers (1) - Contour washer (2) - 1st tensioning washer (3) - 2nd tensioning washer (4) - Rubber o-ring (5) - Adjusting nut (6) - Grub screw Service Instructions 650-16 Version 00.0 - Last Updated 09/2012...

  • Page 52: Adjusting The Spring Force

    6. Tighten the grub screw on the cylinder (3). 7. Insert the inner cylinder (2) into the thread tensioner. 8. Tighten the grub screw (1). 9. Fitting the electrical thread tensioner ( Chap. 15.1, p. 46). Service Instructions 650-16 Version 00.0 - Last Updated 09/2012...

  • Page 53: Adjusting The Spring Stroke

    1. Loosen the grub screw (2). 2. Turn the complete bushing (3) to achieve the desired spring stroke: • Longer spring stroke: Turn clockwise • Shorter spring stroke: Turn anticlockwise 3. Tighten the grub screw (2). Service Instructions 650-16 Version 00.0 - Last Updated 09/2012...

  • Page 54: Adjusting The Thread Regulator

    2. Loosen the fastening screw (2). 3. Displace the thread regulator (1). • Larger thread length: Push regulator to left • Shorter thread length: Push regulator to right 4. Tighten the fastening screw (2). Service Instructions 650-16 Version 00.0 - Last Updated 09/2012...

  • Page 55: Adjusting The Bobbin Winder

    4. Release the adjusting screw (1). 5. Move the thread guide plate (3). • Smaller fill volume: Push towards bobbin • Larger fill volume: Push away from bobbin 6. Tighten the adjusting screw (1). Service Instructions 650-16 Version 00.0 - Last Updated 09/2012...

  • Page 56: Setting The Winding Form Of The Bobbin Winder

    Malfunctions in case of incorrect settings. • Wrinkled seams • Poor sewing results Adjusting steps 1. Turn the adjusting knob (2): • Greater tension: Turn clockwise • Less tension: Turn anticlockwise Service Instructions 650-16 Version 00.0 - Last Updated 09/2012...

  • Page 57: Service Settings Via Software

    The arrow keys let you move from entry to entry: Moving with the arrow keys •  in a list of menu items /  adjacently in value fields • / Service Instructions 650-16 Version 00.0 - Last Updated 09/2012...

  • Page 58: Accessing Technician Level

    For safety reasons, the figures are not displayed. A 0 is displayed at the entry point, and an asterisk at all other points. You can press  to move from one entry point to / another. Service Instructions 650-16 Version 00.0 - Last Updated 09/2012...
  • Page 59 Only the two submenus are available. Multitest Reset • : Tests for error diagnostics ( p. 63) Multitest • : Reset the machine to the factory defaults ( p. 72) Reset all Service Instructions 650-16 Version 00.0 - Last Updated 09/2012...

  • Page 60: Menu Items At Technician Level

    = After programming the 1st teach 2nd sleeve side sleeve side, also program the 2nd sleeve side • = After programming the 1st sleeve side, the selection mask for nothing mirror teach appears Service Instructions 650-16 Version 00.0 - Last Updated 09/2012...

  • Page 61: Menu Item Machine Config

    Submenu End Tack This submenu is identical to the submenu . The same set- Start Tack End Tack tings are made for the end tack. ( Section Submenu Start Tack, p. Service Instructions 650-16 Version 00.0 - Last Updated 09/2012...
  • Page 62 4000 Speed is fully depressed Speed for positioning 10 – 700 Pos. Speed Soft Speed Speed for softstart stitches 10 – 1000 N Stitches Number of softstart stitches 1 – 10 Service Instructions 650-16 Version 00.0 - Last Updated 09/2012...
  • Page 63 1 = Sewing foot lifting Sewing foot lifting after thread 0 = No sewing foot lifting FL After- trimming 1 = Sewing foot lifting Trim FL height Height of lifted foot 0 – 999 Service Instructions 650-16 Version 00.0 - Last Updated 09/2012...

  • Page 64: Menu Item User Config

    1 = Cancel with main pedal Abort Function of the 0 = Additional pedal no function Mode optional additional 1 = Change in fullness Pedal pedal 2= Change in curve support Service Instructions 650-16 Version 00.0 - Last Updated 09/2012...

  • Page 65: Menu Item Service

    Figure 56: Subitems in the submenu Multitest – Subitem Test output Do not select this menu item. The menu item has no assignment on this machine. Service Instructions 650-16 Version 00.0 - Last Updated 09/2012...
  • Page 66 Important: The values shown in the % field do not correspond to the calibrated thread tension values( Section Subitem Thread Calib, p. 69), but only give you some orientation as to the extent to which the tension increases or drops. Service Instructions 650-16 Version 00.0 - Last Updated 09/2012...
  • Page 67 Depress the pedal to various positions. Mode pedal input C Mode pedal input D Reference sensor disk for sewing Turn the handwheel motor State change at top and bottom dead cen- tre of needle. Service Instructions 650-16 Version 00.0 - Last Updated 09/2012...
  • Page 68 The machine is referenced. 2. For press  to enter a speed in steps of 50. / Speed 3. Press The motor runs at the set speed. To quit: 1. Press Service Instructions 650-16 Version 00.0 - Last Updated 09/2012...
  • Page 69 There is no separate test for the step motor encoders. They are tested Test also in- cludes the encod- along with the step motors. If the results for the step motors are OK, the encoders are functional. Service Instructions 650-16 Version 00.0 - Last Updated 09/2012...
  • Page 70 5. Change the value in this field by pressing / • Increase top transport: Increase value • Reduce top transport: Reduce value 6. Repeat the test with the pieces of cardboard. 7. Repeat steps 1 to 6 if needed. Service Instructions 650-16 Version 00.0 - Last Updated 09/2012...
  • Page 71 ( Section Submenu Reset, p. 72) and after loading new software, ( Section Installing software with a dongle, p. 73) the values are kept. The thread tension only needs to be calibrated after changing the control unit. Service Instructions 650-16 Version 00.0 - Last Updated 09/2012...
  • Page 72 8. At the point where the measuring device shows a value of 300 g: tighten the grub screw (3) without changing the position of the adjusting nut (1). 9. Press Service Instructions 650-16 Version 00.0 - Last Updated 09/2012...
  • Page 73 3. Set calibration point 1 1. Press  to select calibration point 1 / 2. Press  until the measuring device reads 3. Change the thread tension with / 5 g. 4. Press Service Instructions 650-16 Version 00.0 - Last Updated 09/2012...
  • Page 74 1. Press to select  / Reset all 2. Press All programs and parameters (except for the calibration values for thread tension and the sewing feet) are reset to the factory defaults. Service Instructions 650-16 Version 00.0 - Last Updated 09/2012...

  • Page 75: Installing Software With A Dongle

    (1) - Firmware version 3000 2012-02-15 (2) - Software version 3000 V00.54 2012-02-15 2012-07-02 4. Remove the dongle.  This completes the software transfer. The machine is ready for sew- ing. Service Instructions 650-16 Version 00.0 - Last Updated 09/2012...

  • Page 76: Checking The Key Functionality At The Control Panel

    Figure 72: Status message for fully functional keys 5.Press • If one or more keys are not functional: The display shows the following status message: Keys The control panel must be replaced. Service Instructions 650-16 Version 00.0 - Last Updated 09/2012...

  • Page 77: Maintenance Work

    Once a year, you must lubricate the following areas of the machine head with grease: • Joints on the gearbox: • Needle bar Figure 73: Lubricating the joints on the machine head (1) - Joints on the gearbox: (2) - Needle bar Service Instructions 650-16 Version 00.0 - Last Updated 09/2012...

  • Page 78: Cleaning

    This cleaning work is described in the Operating instructions ( Operat- ing instructions Chap. 10 Maintenance). Attention Damage to paint due to solvent-based cleaning agents Solvent-based cleaning agents will damage the machine's paint Only use solvent-free substances to clean the machine. Service Instructions 650-16 Version 00.0 - Last Updated 09/2012...

  • Page 79: Appendix

    • Contact DA Service 1420 Sewing motor power • Sewing motor blocked • Resolve blockage fault • Encoder cable not connected • Check/replace encoder cable or defective • Replace sewing motor • Encoder defective Service Instructions 650-16 Version 00.0 - Last Updated 09/2012...
  • Page 80 2551 Communication with • Signal from additional control • Check/replace cable to additional control additional control does not exist • Replace additional control (9850 650001) • Replace control unit (9850 650002) Service Instructions 650-16 Version 00.0 - Last Updated 09/2012...
  • Page 81 • Check plug and cable and replace as needed tialization error DAC3 or X502 on PCB, or • Replace distributor board (9850 650000) defective • Cable 120t-L021A defective • Distributor board defective Service Instructions 650-16 Version 00.0 - Last Updated 09/2012...
  • Page 82 • Replace distributor board (9850 650000) cable defective • Plug 140t not plugged in to DAC3 or X503 on PCB, or defective, or cable X140t-L023 defective • Distributor board defective Service Instructions 650-16 Version 00.0 - Last Updated 09/2012...

  • Page 83: Circuit Diagram

    Appendix 20.2 Circuit diagram Circuit diagram - Sheet 1 Service Instructions 650-16 Version 00.0 - Last Updated 09/2012...
  • Page 84 Appendix Circuit diagram - Sheet 2 Service Instructions 650-16 Version 00.0 - Last Updated 09/2012...
  • Page 85 Appendix Circuit diagram - Sheet 3 Service Instructions 650-16 Version 00.0 - Last Updated 09/2012...
  • Page 86 Appendix Circuit diagram - Sheet 4 Service Instructions 650-16 Version 00.0 - Last Updated 09/2012...
  • Page 87 Appendix Circuit diagram - Sheet 5 Service Instructions 650-16 Version 00.0 - Last Updated 09/2012...
  • Page 88 Appendix Circuit diagram - Sheet 6 Service Instructions 650-16 Version 00.0 - Last Updated 09/2012...
  • Page 89 Appendix Circuit diagram - Sheet 7 Service Instructions 650-16 Version 00.0 - Last Updated 09/2012...
  • Page 90 Appendix Service Instructions 650-16 Version 00.0 - Last Updated 09/2012...
  • Page 92 DÜRKOPP ADLER AG Potsdamer Straße 190 33719 Bielefeld GERMANY Phone +49 (0) 521 / 925-00 E-mail marketing@duerkopp-adler.com www.duerkopp-adler.com...

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