Dürkopp Adler 195 Service Instructions Manual
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Dürkopp Adler 195 Service Instructions Manual

Dürkopp Adler 195 Service Instructions Manual

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Summary of Contents for Dürkopp Adler 195

  • Page 1 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 2017...

  • Page 3: Table Of Contents

    Setting the timing of the feeding foot feed movement ....53 Setting the stroke adjusting range and the timing of the feeding foot stroke movement ............ 55 Setting the precise sewing foot timing ........58 Sewing foot lift ................59 Service Instructions 195 - 00.0 - 12/2017...
  • Page 4 113 Inserting the thread divider on 2-needle machines..... 114 Programming ................115 24.1 Buttons on the control panel ............. 116 24.2 Activating the tensioner lift............119 24.3 Activating stitch condensing ............. 119 Service Instructions 195 - 00.0 - 12/2017...
  • Page 5 28.1 Customer Service ..............139 28.2 Messages of the software............139 Errors in sewing process ............146 28.3 Technical data................. 149 Appendix ................. 151 30.1 Wiring diagram ................. 151 30.2 Pneumatic diagram..............153 Service Instructions 195 - 00.0 - 12/2017...
  • Page 6 Table of Contents Service Instructions 195 - 00.0 - 12/2017...

  • Page 7: About These Instructions

    Steps to be performed for service, maintenance, and installation Steps to be performed via the software control panel The individual steps are numbered: First step Second step The steps must always be followed in the specified order. … Service Instructions 195 - 00.0 - 12/2017...
  • Page 8 Safety ( p. 9). If no other clear location information is used in a figure, indications of right Location information or left are always from the user's point of view. Service Instructions 195 - 00.0 - 12/2017...

  • Page 9: Other Documents

    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 195 - 00.0 - 12/2017...
  • Page 10 About these instructions Service Instructions 195 - 00.0 - 12/2017...

  • Page 11: Safety

    • Set up the machine/put the machine into operation • Perform maintenance work and repairs • Perform work on electrical equipment Only authorized persons may work on the machine and must first have understood these instructions. Service Instructions 195 - 00.0 - 12/2017...

  • 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 195 - 00.0 - 12/2017...
  • 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 195 - 00.0 - 12/2017...
  • 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 195 - 00.0 - 12/2017...

  • Page 15: Working Basis

    1. Lay any excess cabling neatly in proper cable snakes. 2. Bind together the cable loops with cable ties. Important Tie loops wherever possible to fixed parts. The cables must be secured firmly. 3. Cut off any overlapping cable ties. Service Instructions 195 - 00.0 - 12/2017...

  • Page 16: Using Adjustment Aids

    0933 000740 • Set the height of the thread take-up Gage disk 0933 000758 • Set the pusher eccentric for Gage the feed dog (accessory pack) 0491 079996 • Set the quick stroke function of Gage the sewing feet Service Instructions 195 - 00.0 - 12/2017...

  • Page 17: Setting The Handwheel Into Position

    Some settings require that the handwheel be moved to a certain position. To set the handwheel to the desired position: 1. Turn the handwheel until the desired letter (2) is parallel to the marking (1). Service Instructions 195 - 00.0 - 12/2017...

  • Page 18: Flats On Shafts

    Always ensure that the screws are completely flush with the surface. 3.6 Locking the machine in place Fig. 3: Locking the machine in place (1) ③ ① ② (1) - Locking peg (3) - Handwheel (2) - Locking opening Service Instructions 195 - 00.0 - 12/2017...
  • Page 19 3. Turn the handwheel (3) slightly forward or backward until the peg engages in the corresponding hole. Position A of the adjusting disk (8) has the deepest slot. Positions B, D, E and F have the same depths. Service Instructions 195 - 00.0 - 12/2017...
  • Page 20 • Symmetry of the hook movement Removing the lock To remove the lock: 1. Pull the locking peg (1) out of the locking opening (2).  The machine is no longer locked in place. Service Instructions 195 - 00.0 - 12/2017...

  • Page 21: Tilting And Erecting The Machine Head

    Tilting the machine head To tilt the machine head: 1. Carefully tilt the machine head up to the tilt protection device (1). Erecting the machine head To erect the machine head: 1. Erect the machine head. Service Instructions 195 - 00.0 - 12/2017...

  • Page 22: Removing The Covers

    Cable at the control panel may be crushed or torn off. Do not kink, crush or tear off the cable at the control panel. Fig. 6: Removing and placing the arm cover (1) ① ② (1) - Arm cover (2) - Screw Service Instructions 195 - 00.0 - 12/2017...
  • Page 23 2. Carefully remove the arm cover (1) without crushing or kinking the cable of the control panel. Placing the arm cover To place the arm cover: 1. Place the arm cover (1). 2. Tighten the screws (2). Service Instructions 195 - 00.0 - 12/2017...

  • Page 24: Removing And Placing The Head Cover

    (2) - Push buttons 1. Loosen the screws (3). Fig. 9: Removing and placing the head cover (2)  The external lamp (1) and the push buttons (2) are now hanging down loosely. Service Instructions 195 - 00.0 - 12/2017...
  • Page 25 To place the head cover: 1. Place the head cover (6) such that the locking button (8) is inserted properly. 2. Tighten the screws (7). 3. Tighten the bracket (5) using the screws (4). Service Instructions 195 - 00.0 - 12/2017...

  • Page 26: Removing And Placing The Rear Cover

    Fig. 12: Removing and placing the rear cover ① ② (1) - Rear cover (2) - Screw Important When removing and replacing the rear cover, make sure not to pull off or pinch any cables. Service Instructions 195 - 00.0 - 12/2017...

  • Page 27: Removing And Placing The Oil Collection Tray On The Underside Of The Machine

    Placing the oil collection tray on the underside of the machine To place the oil collection tray on the underside of the machine: 1. Place the oil collection tray (1). 2. Re-tighten the screw (2). Service Instructions 195 - 00.0 - 12/2017...

  • Page 28: Removing And Placing The Grease Cap

    Fig. 15: Removing and placing the grease cap (2) ② ③ (2) - Screw (3) - Grease cap 3. Remove the lower cover ( p. 25). 4. Loosen the screw (2). 5. Remove the grease cap (3). Service Instructions 195 - 00.0 - 12/2017...
  • Page 29 To place the grease cap: 1. Place the grease cap (3). 2. Tighten the screw (2). 3. Place the lower cover ( p. 25). 4. Erect the machine head ( p. 19). 5. Tighten the screw (1). Service Instructions 195 - 00.0 - 12/2017...

  • Page 30: Removing And Placing The Toothed Belt Cover

    To place the toothed belt cover: 1. Carefully place the toothed belt cover (1) without crushing, kinking or pinching any cables. 2. Tighten the 5 screws (3). 3. Place the handwheel (2) ( p. 29). Service Instructions 195 - 00.0 - 12/2017...

  • Page 31: Removing And Placing The Handwheel

    2. Remove the handwheel (1). To place the handwheel: 1. Position the handwheel (1) such that it lines up with the toothed belt cover (3). 2. Tighten the handwheel (1) using the screws (2). Service Instructions 195 - 00.0 - 12/2017...

  • Page 32: Opening And Closing The Hook Covers

    1. Carefully pry open hook covers (1) and (2) using, for instance, a pair of tweezers. Fig. 20: Opening and closing the hook covers (2) 2. Remove both hook covers (1) and (2). Fig. 21: Opening and closing the hook covers (3) Service Instructions 195 - 00.0 - 12/2017...

  • Page 33: Disassembling And Assembling The Throat Plate

    1. Lock the sewing feet in place at the top ( Operating Instructions). 2. Open the hook covers ( p. 30). 3. Loosen the 2 screws (2). 4. Remove the throat plate (1). Service Instructions 195 - 00.0 - 12/2017...

  • Page 34: Disassembling And Assembling The Feed Dog

    3. Close the hook cover ( p. 30). 3.12 Disassembling and assembling the feed dog Fig. 24: Disassembling and assembling the feed dog ① ② ③ (1) - Throat plate (3) - Screw (2) - Feed dog Service Instructions 195 - 00.0 - 12/2017...
  • Page 35 2. Tighten the screw (3). 3. Assemble the throat plate ( p. 31). 4. Close the hook covers ( p. 30). Order Then check the following setting: • Feed dog ( p. 80) Service Instructions 195 - 00.0 - 12/2017...
  • Page 36 Working basis Service Instructions 195 - 00.0 - 12/2017...

  • Page 37: Setting The Adjusting Disk Relative To The Arm Shaft Crank

    (1) - Position F (5) - Position D  (2) - Locking peg (locking peg 3, p. 14) (6) - Adjusting disk (3) - Position A (7) - Position B (4) - Position E Service Instructions 195 - 00.0 - 12/2017...
  • Page 38 (2) through the locking opening (8) and into the slot of the arm shaft crank (9). Fig. 27: Setting the adjusting disk relative to the arm shaft crank (3) ⑪ ⑩ (10) - Locking washer (11) - Cylinder Service Instructions 195 - 00.0 - 12/2017...
  • Page 39 4. Turn the handwheel until the threaded pin (12) in the toothed belt (13) can be accessed from the top. 5. If necessary, move the toothed belt (14) slightly to the left to gain access to the threaded pin (12). 6. Loosen the threaded pin (12). Service Instructions 195 - 00.0 - 12/2017...
  • Page 40 12. Slide the cylinder (11) all the way back to the right. 13. Secure the cylinder (11) with the locking washer (10). 14. To remove the lock, pull out both locking pegs (2) ( p. 16). Service Instructions 195 - 00.0 - 12/2017...

  • Page 41: Needle Bar Linkage

    ⑤ (5) - Guide pin The needle bar linkage of class 195 is split into two sections. The station- ary part with the needle bar (3) is screwed directly to the body casting. The other part with the feeding foot bar (2) is fitted so that it can move freely.

  • Page 42: Setting The Linkage Holder

    The linkage holder (2) must be in the horizontal position. Cover • Remove the head cover ( p. 22). To set the linkage holder: 1. Tighten the nuts (1) so that the linkage holder (2) is in the horizontal position. Service Instructions 195 - 00.0 - 12/2017...

  • Page 43: Setting The Distance Between Feeding Foot Bar And

    (1) - Feeding foot bar (2) - Cloth pressure bar Fig. 34: Setting the distance between feeding foot bar and cloth pressure bar (2) ③ ④ ⑤ (3) - Support plate (5) - Eccentric (4) - Screw Service Instructions 195 - 00.0 - 12/2017...
  • Page 44 5. Remove the support plate (3). 6. Set the eccentric (5) to a distance of 11 mm between the feeding foot bar (1) and the cloth pressure bar (2). 7. Tighten the threaded pin behind the plug (6). Service Instructions 195 - 00.0 - 12/2017...

  • Page 45: Adjusting Wheels

    Fig. 37: Setting the adjusting wheels for stitch length, stitch length limit and stitch condensing (2) ③ ⑥ ⑧ ⑦ (3) - Adjusting wheel (for top feed) (7) - Stop pin (6) - Locking screw (8) - Cam Service Instructions 195 - 00.0 - 12/2017...
  • Page 46 1. To increase stitch condensing, turn the adjusting screw (1) towards +. 2. To reduce stitch condensing, turn the adjusting screw (1) towards -. Important To ensure a proper seam pattern, the stitch length MUST be at least 2.5 mm with stitch condensing enabled. Service Instructions 195 - 00.0 - 12/2017...

  • Page 47: Setting The Adjusting Wheel For The Sewing Foot Stroke

    Fig. 39: Setting the adjusting wheel for the sewing foot stroke (1) ① (1) - Curve Fig. 40: Setting the adjusting wheel for the sewing foot stroke (2) ① ② (1) - Curve (2) - Ball head Service Instructions 195 - 00.0 - 12/2017...
  • Page 48 5. Tighten the screw (4). 6. Verify that there is still no play between curve (1) and ball head (2) when the adjusting wheel (3) is set to 2 mm. 7. Correct the setting again if necessary. Service Instructions 195 - 00.0 - 12/2017...

  • Page 49: Setting The Potentiometer

    If the display (1) indicates a different level: 2. Call up the technician level using the Plus/Minus buttons: As the case may be, press the Plus/Minus button below the letter or the number until the display indicates t 10 04. Service Instructions 195 - 00.0 - 12/2017...
  • Page 50 Fig. 43: Setting the potentiometer (2) ② (2) - Hole 4. Loosen the threaded pin through the hole (2). Fig. 44: Setting the potentiometer (3) ④ ③ (3) - Locking ring (4) - Potentiometer axle Service Instructions 195 - 00.0 - 12/2017...

  • Page 51: Setting The Maximum Stroke Stop

    Fig. 45: Setting the maximum stroke stop (1) ① (1) - Button When the maximum stroke is switched on, the maximum stroke height of the sewing feet should be 7 mm. Service Instructions 195 - 00.0 - 12/2017...
  • Page 52 (3) - Screw To set the stop for the maximum stroke: 1. If necessary, remove needle and hook thread from the tensioner elements. 2. Loosen the screws (3). 3. Remove the tensioning plate (2). Service Instructions 195 - 00.0 - 12/2017...
  • Page 53  The maximum stroke height must not exceed 7 mm. 6. Adjust the stroke height if necessary: • Increase the stroke height: Screw in the threaded pin (4) further • Reduce the stroke height: Unscrew the threaded pin (4) further Service Instructions 195 - 00.0 - 12/2017...

  • Page 54: Setting The Balance Weight

    Setting the balance weight Setting the balance weight Subclasses 195-171120-01 and 195-171521-01 (part numbers 0195 990001 and 0195 990002) are equipped with a balance weight. Cover • Remove the arm cover ( p. 20). Fig. 48: Setting the balance weight ①...

  • Page 55: Sewing Feet

    Proper setting The sewing foot must not move when the stitch adjustment lever (1) is pressed with the stitch length set to the largest value and the machine locked in place at position B. Service Instructions 195 - 00.0 - 12/2017...
  • Page 56 1. Lock the machine in place at position B ( p. 16). 2. Loosen the threaded pins (4). 3. Turn the pusher eccentric (3) on the arm shaft such that the feeding foot remains at rest when the stitch adjustment lever (1) is pressed. Service Instructions 195 - 00.0 - 12/2017...

  • Page 57: Setting The Stroke Adjusting Range And The Timing Of The Feeding Foot Stroke Movement

    Fig. 51: Setting the stroke adjusting range and the timing of the feeding foot stroke movement (1) ① ④ ② ③  (1) - Gage (gage 9, p. 14) (3) - Screw (2) - Block (4) - Stroke rocker Service Instructions 195 - 00.0 - 12/2017...
  • Page 58 • Feeding foot: 2 mm • Presser foot: 1.8 mm Cover • Remove the arm cover ( p. 20). • Remove the head cover ( p. 22). Service Instructions 195 - 00.0 - 12/2017...
  • Page 59 14) (13) - Locking opening 4. Insert the 2nd locking peg (12) into the locking opening (13).  The sliding block (8) of the rocker must abut on the locking pin (7). Service Instructions 195 - 00.0 - 12/2017...

  • Page 60: Setting The Precise Sewing Foot Timing

    To set the precise sewing foot timing: 1. Lock the machine in place at position D ( p. 16). 2. Slightly shift the eccentric (1) at its initial position (slot is horizontal in the upper semicircle). Service Instructions 195 - 00.0 - 12/2017...

  • Page 61: Sewing Foot Lift

    When working with particularly thick sewing feet, e.g. piping feet, you must reduce the distance as much as necessary to prevent a collision with the needle bar. Cover • Remove the arm cover ( p. 20). Service Instructions 195 - 00.0 - 12/2017...

  • Page 62: Setting The Intercept Buffer

    The intercept buffer prevents the sewing feet from resting directly on the throat plate. Proper setting The distance between throat plate and sewing feet should be 0.2-0.8 mm depending on the sewing material. Cover • Remove the head cover ( p. 22). Service Instructions 195 - 00.0 - 12/2017...

  • Page 63: Setting The Height Of The Locked Sewing Feet

    The distance of the raised and locked sewing feet to the throat plate should be 10 mm. Fig. 59: Setting the height of the locked sewing feet (1) ① (1) - Locking button Service Instructions 195 - 00.0 - 12/2017...
  • Page 64 • Remove the head cover ( p. 22). To set the height of the locked sewing feet: 1. Loosen the screws (2). 2. Change the position of the support plate (3). 3. Re-tighten the screws (2). Service Instructions 195 - 00.0 - 12/2017...

  • Page 65: Setting The Left Lower Shaft Bearing

    To set the left lower shaft bearing: 1. Tilt the machine head ( p. 19). 2. Disassemble the throat plate ( p. 31). 3. Disassemble the thread cutter. 4. Disassemble the hook carrier with needle guard and hook. Service Instructions 195 - 00.0 - 12/2017...
  • Page 66 (4) is pulled off. 6. Loosen the screw (7) along with all elements screwed to the lower shaft. 7. Carefully pull the hook drive housing (4) off to the left along with the lower shaft. Service Instructions 195 - 00.0 - 12/2017...
  • Page 67 12. Assemble and set the hook drive housing (4) and the lower shaft ( p. 66). 13. Fill the hook drive housing (4) with DA 10 lubricating oil ( p. 125). 14. Check the oil level of the hook drive housing (4) ( p. 127). Service Instructions 195 - 00.0 - 12/2017...

  • Page 68: Setting The Hook Drive Housing

    4. Tighten the gage (1) on the throat plate support. 5. Press the hook shaft up to the gage (1). 6. Tighten the hook drive housing. 7. Assemble and set all previously disassembled parts. Service Instructions 195 - 00.0 - 12/2017...

  • Page 69: Setting The Needle Evasive Movement Of The Hook (Ellipsis Width)

    Distance of hook tip to needle = 0.1 mm For larger needle thickness 110 Nm X *= 0.1 mm Ellipsis width E = 2.3 mm *X = larger dimension a for larger needle thicknesses Service Instructions 195 - 00.0 - 12/2017...
  • Page 70 6. To move the hook shaft to the highest position, turn the handwheel.  The difference must match the previously calculated ellipsis width. To set the ellipsis width, you must move the rocker bolt in the hook hous- ing in axial direction. Service Instructions 195 - 00.0 - 12/2017...
  • Page 71 4. Take off the cover (5) and catch any leaking oil using the clean cloth. Fig. 68: Setting the needle evasive movement of the hook (4) ⑧ ⑦ (7) - Threaded pin (8) - Rocker bolt Service Instructions 195 - 00.0 - 12/2017...
  • Page 72 7. To slide the rocker bolt (8), push or pull the M4 screw: • Ellipsis width increases: Slide the rocker bolt (8) to the left • Ellipsis width decreases: Slide the rocker bolt (8) to the right 8. Check the oil level ( p. 125). Service Instructions 195 - 00.0 - 12/2017...

  • Page 73: Setting The Symmetry Of The Hook

    The hook tip should be in front of and behind the needle in position E and position F, respectively. Fig. 70: Setting the symmetry of the hook (2) ③ ① ② (1) - Screw (3) - Pointer  (2) - Gage (gage 6, p. 14) Service Instructions 195 - 00.0 - 12/2017...
  • Page 74 2. Turn the lower shaft such that the pointer (3) is above the marking on the gage (2) both at position E and F. 3. Tighten the fastening screws of the toothed belt wheel again. Service Instructions 195 - 00.0 - 12/2017...

  • Page 75: Setting The Hook In The Hook Carrier

    Fig. 71: Setting the hook in the hook carrier (1) ① (1) - Screw To set the hook in the hook carrier: 1. Loosen the screw (1) of the hook carrier. Service Instructions 195 - 00.0 - 12/2017...
  • Page 76 ② (2) - Hook (4) - Edge (3) - Gage 2. Position the gage (3) at the edge (4). 3. Move the hook (2) to the correct position. 4. Re-tighten the screw (1). Service Instructions 195 - 00.0 - 12/2017...

  • Page 77: Setting Loop Stroke And Needle Bar Height

    Fig. 74: Setting loop stroke and needle bar height (2) ① ① ② (1) - Screw (2) - Screw To set the loop stroke and the needle bar height: 1. Insert a new needle ( Operating Instructions). Service Instructions 195 - 00.0 - 12/2017...
  • Page 78 (5) and groove (6). 10. Tighten the screw (1). 11. Check the symmetry of the hook (positions E and F) ( p. 71). 12. Insert the plug (3) back into the hole. Service Instructions 195 - 00.0 - 12/2017...

  • Page 79: Needle Guard And Needle Guard Plate

    In this position, the needle must touch the needle guard. The timing of the needle guard movement cannot be altered. Fig. 77: Setting the needle guard (1) Service Instructions 195 - 00.0 - 12/2017...
  • Page 80 4. Use the screw (1) to move the needle guard towards the needle until it is close enough for you to push it into the area of the hook. The needle must not be pushed aside any more than is required. 5. Tighten the nut (2). Service Instructions 195 - 00.0 - 12/2017...

  • Page 81: Setting The Needle Guard Plate

    2. Disassemble the throat plate ( p. 31). 3. Loosen the screw (3). 4. Set the needle guard plate (2) such that the needle (1) passes freely between hook and needle guard plate (2). 5. Tighten the screw (3). Service Instructions 195 - 00.0 - 12/2017...

  • Page 82: Feed Dog

    1. Tilt the machine head ( p. 19). 2. Loosen the screw (1) on the advance lever. 3. Place the feed dog at the appropriate position. 4. Tighten the screw (1) on the advance lever. Service Instructions 195 - 00.0 - 12/2017...
  • Page 83 2. Major deviations require that you loosen the screw (1) on the advance lever. 3. Loosen the screw (2) on the stroke lever. 4. Adjust the position of the feed dog carrier. 5. Tighten the screw (2). 6. Tighten the screw (1). Service Instructions 195 - 00.0 - 12/2017...

  • Page 84: Setting The Height Of The Feed Dog

    1. Tilt the machine head ( p. 19). 2. To adjust the height of the feed dog when necessary, loosen the screw (1) on the stroke lever. 3. Adjust the height of the feed dog. 4. Tighten the screw (1). Service Instructions 195 - 00.0 - 12/2017...

  • Page 85: Setting The Thrust Movement Of The Feed Dog

    Fig. 83: Setting the thrust movement of the feed dog (1) ① (1) - Oil collection tray To set the thrust movement of the feed dog: 1. Tilt the machine head ( p. 19). Service Instructions 195 - 00.0 - 12/2017...
  • Page 86 5. Turn the pusher eccentric (5) such that the edges of the gage (3) rest on the stitch adjustment linkage (2). 6. Tighten the screws of the pusher eccentric (5). 7. Check if the lower shaft has axial play. Service Instructions 195 - 00.0 - 12/2017...

  • Page 87: Setting The Stroke Movement Of The Feed Dog

    (2) - Oil collection tray To set the stroke movement of the feed dog: 1. Tilt the machine head ( p. 19). 2. Loosen the screw (3). 3. Lock the machine in place at position B. Service Instructions 195 - 00.0 - 12/2017...

  • Page 88: Setting The Initial Position Of The Stitch Regulator For Top Feed

    Fig. 87: Setting the initial position of the stitch regulator for top feed (1) ① (1) - Adjusting wheel (for stitch length during top feed) Service Instructions 195 - 00.0 - 12/2017...
  • Page 89  The initial position of the stitch regulator for top feed has been set. 4. Tighten the screw (3) on the clamping block (2). 5. Check the synchronization of top feed and bottom feed and adjust it if necessary ( p. 88). Service Instructions 195 - 00.0 - 12/2017...

  • Page 90: Setting The Synchronization Of Top And Bottom Feed

    4. Switch on the machine ( Operating Instructions). 5. To feed the 2 layers of fabric, press the pedal to position 1. 6. Check if both layers of fabric are fed in sync. Service Instructions 195 - 00.0 - 12/2017...
  • Page 91 2. Check the synchronization of top and bottom feed again. 3. If both layers of fabric are not fed in sync, set the initial position of the stitch regulator for bottom feed ( p. 90). Service Instructions 195 - 00.0 - 12/2017...

  • Page 92: Setting The Initial Position Of The Stitch Regulator For Bottom Feed

    To set the initial position of the stitch regulator for bottom feed: 1. Set the adjusting wheel (1) to the same stitch length as the length used for top feed. 2. Tilt the machine head ( p. 19). Service Instructions 195 - 00.0 - 12/2017...
  • Page 93 3. Loosen the threaded pin (2). 4. Move the clamping block (3) on the shaft. 5. Tighten the threaded pin (2). 6. Check if top and bottom feed are now in sync ( p. 88). Service Instructions 195 - 00.0 - 12/2017...

  • Page 94: Setting The Thread Take-Up Disk

    3. Loosen the threaded pins of the thread take-up disk (2). 4. Lock the machine in place at position B ( p. 16). 5. Turn the thread take-up disk (2) accordingly. Use the gage (4) to set the correct measurement. Service Instructions 195 - 00.0 - 12/2017...
  • Page 95 Setting the thread take-up disk Fig. 94: Setting the thread take-up disk (2) 6. Tighten the take-up disk (2) and the screws. Service Instructions 195 - 00.0 - 12/2017...

  • Page 96: Setting The Retention Spring On The Hook

    Fig. 95: Setting the retention spring on the hook ⑤ ④ 0.5 mm ③ ① ② (1) - Holding point (4) - Hook (2) - Retention spring (5) - Needle thread loop (3) - Screw Service Instructions 195 - 00.0 - 12/2017...
  • Page 97 • To increase the contact pressure: Align the retention spring (2) if the needle thread loop (5) is not held at the holding point (1) until the needle plunges into the thread triangle on the left in front of the needle thread loop (5). Service Instructions 195 - 00.0 - 12/2017...

  • Page 98: Setting The Thread Cutter

    ① (1) - Point (2) - Counter blade Subclass 195-171521-01 is equipped with a thread cutter. Proper setting During thread cutting, needle and hook thread are picked up behind the hook by the movable blade (1) and pressed against the cutting edge of the counter blade (2).

  • Page 99: Disassembling The Thread Cutter

    4. Loosen the 2 screws (1). 5. Loosen the screw (4). 6. Remove the thread cutter (3). Fig. 98: Disassembling the thread cutter (2) ③ (3) - Thread cutter (view from the bottom) Service Instructions 195 - 00.0 - 12/2017...

  • Page 100: Performing A Manual Cutting Test

    (8) - Counter blade To perform a manual cutting test: 1. Disassemble the thread cutter ( p. 97). Fig. 100: Performing a manual cutting test (2) ⑨  (9) - Gage (gage 12, p. 14) Service Instructions 195 - 00.0 - 12/2017...
  • Page 101 8. If necessary, set the movable blade (5) to its cutting position by carefully aligning the intermediate plate (7) until the cut is made reliably. 9. Unscrew the thread cutter from the gage (9). 10. Assemble the thread cutter back into the machine. Service Instructions 195 - 00.0 - 12/2017...

  • Page 102: Setting The Position Of The Movable Blade

    3. Tilt the machine head ( p. 19). Right position 4. Manually move the thread cutter to the right end position. 5. Use the fork head (7) to set the right position and secure it using the counternut (6). Service Instructions 195 - 00.0 - 12/2017...
  • Page 103 7. Slightly loosen the counternut (6). 8. Set the fork head (7) on the piston rod (5) such that the outer edge (2) of the thread cutter is flush with the outer edge of the machine housing (1). Service Instructions 195 - 00.0 - 12/2017...

  • Page 104: Replacing The Movable Blade

    5. Tighten the threaded pins (1). 6. Align the counter blade (3) so that the notch is level with the edge of the mounting plate (4). 7. Tighten the counter blade (3). 8. Test the cut. Service Instructions 195 - 00.0 - 12/2017...
  • Page 105 Setting the thread cutter Fig. 105: Replacing the movable blade (2) 9. Check the end position of the movable blade (2) and set it if necessary ( p. 100). Service Instructions 195 - 00.0 - 12/2017...

  • Page 106: Setting The Thread Advancing Device For Needle And Hook Thread

    Fig. 107: Setting the thread advancing device for needle and hook thread (2) ① ② ③ ④ (1) - Thread advancing device (3) - Nose (2) - Stop (4) - Flight of steps Service Instructions 195 - 00.0 - 12/2017...
  • Page 107  The thread advancing device (1) extends less far. • Advance more thread: The stop (2) may protrude less far into the thread advancing device (1).  The thread advancing device (1) extends further. Service Instructions 195 - 00.0 - 12/2017...

  • Page 108: Edge Cutter

    Edge cutter 21 Edge cutter Class 195-671120-01 (mat. no. 0195 990003) is equipped with an edge cutter. 21.1 Setting the knife stroke WARNING Risk of injury! Crushing, cutting and punctures are possible. Only set the knife stroke with the machine switched off.

  • Page 109: Setting The Top Blade In Seam Direction

    When the top blade is at the bottom dead center with the edge cutter switched on, the front tip of the knife blade should be approx. 1 mm in front of the needle. Service Instructions 195 - 00.0 - 12/2017...

  • Page 110: Setting The Cutter Bar Standstill During Shut-Off

    Proper setting When the edge cutter is switched off, the cutter bar should only make the slightest movement (a complete standstill is not possible). Cover • Remove the arm cover ( p. 20). Service Instructions 195 - 00.0 - 12/2017...
  • Page 111 1. Loosen the screw (2) on the clamping piece (3). 2. Turn the pull rod (1) such that the cutter bar makes only the slightest movement when the handwheel is turned. 3. Re-tighten the screw (2). Service Instructions 195 - 00.0 - 12/2017...

  • Page 112: Setting The Height And Lateral Position Of The Top Blade

    Fig. 112: Setting the height and lateral position of the top blade (1) ③ ① ② 1 mm (1) - Top blade (3) - Front tip (2) - Long point Service Instructions 195 - 00.0 - 12/2017...
  • Page 113 9. Loosen the screw (6). 10. Align the point of the blade with the counter blade. 11. Tighten the screw (6). 12. Carry out a cutting test. 13. Adjust the settings again if necessary. Service Instructions 195 - 00.0 - 12/2017...

  • Page 114: Setting The Eccentric On The Upper Shaft

    2. Turn the handwheel until the machine is in the 1 needle position. 3. Adjust the blade drive eccentric (1) such that the 1 screw lines up with the pull rod (2). 4. Tighten the screws on the blade drive eccentric (1) again. Service Instructions 195 - 00.0 - 12/2017...

  • Page 115: Adapting The Thread Guides To Thicker Needle/Hook Threads

    To adjust the hook thread guide: 1. As shown, insert the hook thread at the thread guide (4) on the unwind- ing bracket and do not guide it around the tensioner element (3). Service Instructions 195 - 00.0 - 12/2017...

  • Page 116: Inserting The Thread Divider On 2-Needle Machines

    Replacement hooks can be ordered under the following part numbers: • Hook for left needle: Part number 0195 005055 a • Hook for right needle: Part number 0195 004753 a Service Instructions 195 - 00.0 - 12/2017...

  • Page 117: Programming

    • Read service and error messages. Information This chapter describes the machine-specific functions of the OP1000 control panel. For further information on the control and the OP1000 control panel, refer to the  Instructions for use DAC basic/classic. Service Instructions 195 - 00.0 - 12/2017...

  • Page 118: Buttons On The Control Panel

    • Activates or deactivates the sewing foot lift after the thread cutter Sewing foot lift after sewing stop • Activates or deactivates the sewing foot lift after sewing stops Soft start • Activates or deactivates the soft start Service Instructions 195 - 00.0 - 12/2017...
  • Page 119 • Calls parameter or saves it • Starts or ends the parameter mode • Decreases parameter • Changes user level • Selects subprogram • Decreases parameter • Changes to next lower category • Selects subprogram Service Instructions 195 - 00.0 - 12/2017...
  • Page 120 • Resets the (piece) counter Seam program button group Seam program I • Activates seam program I Seam program II • Activates seam program II Seam program III • Sets seam program III Service Instructions 195 - 00.0 - 12/2017...

  • Page 121: Activating The Tensioner Lift

     You are on the technician level. 2. Use the buttons under the display to select the parameter t 09 00. 3. Use +/- to enter the desired value ( Parameter list 195). 4. Confirm with 24.3 Activating stitch condensing Stitch condensing can be set for the beginning and/or the end of the seam using the control panel.

  • Page 122: Assigning Functions To Buttons On The Push Button Panel

     The control panel shows the value currently set for the button. 3. Use +/- to enter the desired value; see Parameter list 195, parameter t 51 20, for information on which function is assigned which value.

  • Page 123: Assigning A Function To The Knee Button

    The display shows a numerical value / the parameter ( Parameter list 195). 5. Use the buttons + or - to set the numerical value to the desired value associated with the new function ( Parameter list 195). 6. Confirm with Service Instructions 195 - 00.0 - 12/2017...
  • Page 124 Programming Service Instructions 195 - 00.0 - 12/2017...

  • Page 125: Maintenance

    Check oil level in the mist lubricator  Check the oil supply of the mist lubricator  Clean the filter element in the compressed air maintenance unit  Check the tightness of the system Service Instructions 195 - 00.0 - 12/2017...

  • Page 126: Cleaning

    Use only solvent-free substances for cleaning To clean the machine: 1. Remove any lint and thread remnants using a compressed air gun or a brush. 2. Remove any lint and cutting waste from the oil pan. Service Instructions 195 - 00.0 - 12/2017...

  • Page 127: Lubricating

    For topping off the oil reservoir, use only lubricating oil DA 10 or oil of equivalent quality with the following specifications: • Viscosity at 40 °C: 10 mm • Flash point: 150 °C Service Instructions 195 - 00.0 - 12/2017...

  • Page 128: Lubricating The Machine Head

    (4) - Inspection glass Checking the oil level Proper setting The oil level must always be between the minimum level marking (3) and the maximum level marking (2) at the inspection glass (4). Service Instructions 195 - 00.0 - 12/2017...

  • Page 129: Lubricating The Hook

    Hook drive housing and screw plug can be accessed under the right hook cover. Fig. 123: Lubricating the hook (1) ① ② ③ (1) - Screw plug (3) - Dipstick (2) - Hook drive housing Service Instructions 195 - 00.0 - 12/2017...
  • Page 130 3. Loosen the screw plug (1) on the filler opening. 4. Insert the dipstick (3) into the hook drive housing (2). 5. After a few seconds, pull the dipstick (3) out of the hook drive housing (2). Service Instructions 195 - 00.0 - 12/2017...
  • Page 131 4. Check the oil level again. 5. If necessary, repeat step 2 and 3 until the oil level is just below the maximum level marking (5) of the dipstick (3). 6. Tighten the screw plug (1). Service Instructions 195 - 00.0 - 12/2017...

  • Page 132: Servicing The Pneumatic System

    2. Turn the pressure controller until the pressure gage (2) indicates the proper setting: • Increase pressure = turn clockwise • Reduce pressure = turn counterclockwise 3. Push the pressure controller (1) down. Service Instructions 195 - 00.0 - 12/2017...

  • Page 133: Draining The Water Condensation

    2. Place the collection tray under the drain valve (3). 3. Loosen the drain valve (3) completely. 4. Allow water to drain into the collection tray. 5. Tighten the drain valve (3). 6. Connect the machine to the compressed air supply. Service Instructions 195 - 00.0 - 12/2017...

  • Page 134: Cleaning The Filter Element

    6. Wash out the filter tray using benzine. 7. Tighten the filter element (1). 8. Tighten the water separator (2). 9. Tighten the drain valve (3). 10. Connect the machine to the compressed air supply. Service Instructions 195 - 00.0 - 12/2017...

  • Page 135: Parts List

    Maintenance 25.4 Parts list A parts list can be ordered from Dürkopp Adler. Or visit our website for further information at: www.duerkopp-adler.com Service Instructions 195 - 00.0 - 12/2017...
  • Page 136 Maintenance Service Instructions 195 - 00.0 - 12/2017...

  • Page 137: Decommissioning

    5. Cover the control panel to protect it from soiling. 6. Cover the control to protect it from soiling. 7. Cover the entire machine if possible to protect it from contamination and damage. Service Instructions 195 - 00.0 - 12/2017...
  • Page 138 Decommissioning Service Instructions 195 - 00.0 - 12/2017...

  • Page 139: Disposal

    When disposing of the machine, be aware that it consists of a range of different materials (steel, plastic, electronic components, etc.). Follow the national regulations when disposing these materials. Service Instructions 195 - 00.0 - 12/2017...
  • Page 140 Disposal Service Instructions 195 - 00.0 - 12/2017...

  • Page 141: Troubleshooting

    PE) • Replace encoder • Replace sewing motor • Replace control 1002 Error Sewing motor insulation • Check motor phase and PE for fault low-impedance connection • Replace encoder • Replace sewing motor Service Instructions 195 - 00.0 - 12/2017...
  • Page 142 • Check and, if necessary, (during thread cutting, change controller settings. reversal, etc.) Mechanical changes to the machine. (e. g. thread cutting setting, belt tension, etc.) • Check position (thread lever at top dead center) Service Instructions 195 - 00.0 - 12/2017...
  • Page 143 • Check for stiff movement overload 3100 Error AC-RDY timeout, Check mains voltage • - If the mains voltage is OK, intermediate circuit replace the control voltage did not reach the defined threshold in the specified time Service Instructions 195 - 00.0 - 12/2017...
  • Page 144 3215 Information Bobbin stitch counter • Change bobbin, set counter (info value 0 reached) value - press counter reset button 3216 Information Remaining thread • Change the left bobbin monitor left Service Instructions 195 - 00.0 - 12/2017...
  • Page 145 - Switch off the control, wait until the EEprom not connected LEDs are off and then switch on again (the internal data • - Software update structures are not compatible with the external data storage device, emergency operating features only) Service Instructions 195 - 00.0 - 12/2017...
  • Page 146 DAC basic will remain available) 8401 Error Watchdog Software update - Machine ID reset • - Replace the control 8402-8405 Error Internal error Software update - Machine ID reset • - Replace the control Service Instructions 195 - 00.0 - 12/2017...
  • Page 147 Error code Type Possible cause Remedial action 8406 Error Checksum error Software update • - Replace the control 8501 Error Software protection • The DA tool must always be used for software updates Service Instructions 195 - 00.0 - 12/2017...

  • Page 148: Errors In Sewing Process

    • Thread tensions are not adjusted • Check thread tensions to the sewing material, the sewing material thickness or the thread used • Needle thread and hook thread • Check the thread path have not been threaded correctly Service Instructions 195 - 00.0 - 12/2017...
  • Page 149 • Needle thickness is unsuitable for • Use recommended needle breakage the sewing material or the thread Seam beginning • Residual tension is too tight for • Adjust residual tension not secure the needle thread Service Instructions 195 - 00.0 - 12/2017...
  • Page 150 Troubleshooting Service Instructions 195 - 00.0 - 12/2017...

  • Page 151: Technical Data

    3.2 mm, 6 mm (depending on two-needle or 8 mm equipment) Needle bar stroke [mm] Sewing foot stroke [mm] 2.5-7 Mains voltage Mains frequency [Hz] 50/60 Operating pressure [bar] Air consumption [NL] [per cycle] Length [mm] Service Instructions 195 - 00.0 - 12/2017...
  • Page 152 • Integrated cable duct on the back of the arm • Single-piece belt guard • Particularly easy to service thanks to removable head and arm cover • Base plate dimensions 477 x 178 mm Service Instructions 195 - 00.0 - 12/2017...

  • Page 153: Appendix

    Appendix 30 Appendix 30.1 Wiring diagram Fig. 129: Wiring diagram (1) Service Instructions 195 - 00.0 - 12/2017...
  • Page 154 Appendix Fig. 130: Wiring diagram (2) Service Instructions 195 - 00.0 - 12/2017...

  • Page 155: Pneumatic Diagram

    Appendix 30.2 Pneumatic diagram Fig. 131: Pneumatic diagram Service Instructions 195 - 00.0 - 12/2017...
  • Page 156 Appendix Service Instructions 195 - 00.0 - 12/2017...
  • Page 158 DÜRKOPP ADLER AG Potsdamer Str. 190 33719 Bielefeld Germany Phone: +49 (0) 521 925 00 Email: service@duerkopp-adler.com www.duerkopp-adler.com...

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