Duerkopp Adler 506-3 Service Instructions Manual
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Duerkopp Adler 506-3 Service Instructions Manual

Duerkopp Adler 506-3 Service Instructions Manual

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Postfach 17 03 51, D-33703 Bielefeld • Potsdamer Straße 190, D-33719 Bielefeld
Telefon +49 (0) 521 / 9 25-00 • Telefax +49 (0) 521 / 9 25 24 35 • www.duerkopp-adler.com
Ausgabe / Edition:
Änderungsindex
10/2008
Rev. index: 01.0
Instructions, complete

Operating Instructions

Installation Instructions

Service Instructions

Printed in Federal Republic of Germany
506-3
Teile-Nr./Part.-No.:
0791 506011
1
2
3

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Summary of Contents for Duerkopp Adler 506-3

  • Page 1: Operating Instructions

    506-3 Instructions, complete Operating Instructions Installation Instructions Service Instructions Postfach 17 03 51, D-33703 Bielefeld • Potsdamer Straße 190, D-33719 Bielefeld Telefon +49 (0) 521 / 9 25-00 • Telefax +49 (0) 521 / 9 25 24 35 • www.duerkopp-adler.com Ausgabe / Edition: Änderungsindex Teile-Nr./Part.-No.:...
  • Page 2 Instructions, complete 506-3 Overview Operating table Operating Instructions Installation Instructions Service Instructions Pneumatic circuit plan 9770 506002 Interconnection-diagram 9890 506003 B All rights reserved. Property of Dürkopp Adler AG and copyrighted. Reproduction or publication of the content in any manner, even in extracts, without prior written permission of Dürkopp Adler AG, is prohibited.
  • Page 3 Foreword This instruction manual is intended to help the user to become familiar with the machine and take advantage of its application possibilities in accordance with the recommendations. The instruction manual contains important information on how to operate the machine securely, properly and economically. Observation of the instructions eliminates danger, reduces costs for repair and down-times, and increases the reliability and life of the machine.

  • Page 4: General Safety Instructions

    General safety instructions The non-observance of the following safety instructions can cause bodily injuries or damages to the machine. 1. The machine must only be commissioned in full knowledge of the instruction book and operated by persons with appropriate training. 2.

  • Page 5: Table Of Contents

    Contents Page: Part 3: Service Instructions Cl. 506-3 General ........... . Removing the top cover and turning over the upper part of the machine Removing the top cover .
  • Page 6 Contents Page: Thread-burning device 11.1 Thread extractor ..........11.2 Upper burning device .

  • Page 7: General

    1. General These service instructions describe the adjustment of the automatic sewing machine in an appropriate order. CAUTION: Various adjustments are mutually dependent. It is therefore essential for adjustments to be carried out in the order described. CAUTION: The activities described in these servicing instructions may be carried out only by experts or by persons with the appropriate training.

  • Page 8: Removing The Top Cover And Turning Over The Upper Part Of The Machine

    2. Removing the arm cover and Turning over the upper part of the machine 2.1 Removing the arm cover For service work in the interior of the upper part of the machine the arm cover 3 must be removed. First the control unit 1 must be swivelled aside and the bobbin-winder cartridge 2 removed.
  • Page 9 Removing the bobbin-winder cartridge – Undo fixing screws 6. – Lift off bobbin-winder cartridge. Removing the arm cover – Undo arm-cover fixing screws 2. – Carefully raise the arm cover 2 and fold it back. – Remove compressed-air hose 7 from the quick-release fastening: Push the ring 8 to the right and pull the hose out of the quick-release fastening.

  • Page 10: Turning Over The Upper Part Of The Machine

    2.2 Turning over the upper part of the machine For service work on the underside of the upper part of the machine the upper part must be turned over. CAUTION: danger of injury Turn off the main switch. The upper part of the machine must not be turned over unless the main switch is off.

  • Page 11: Shuttle, Needle Bar

    3. Shuttle, needle bar CAUTION: The adjustments described in chapters 3.1 to 3.4 are mutually dependent. It is therefore essential for the individual adjustments to be carried out in the order specified in the service instructions. 3.1 Needle bar height When the shuttle tip extends 2 mm beyond the right-hand side of the needle, the eye of the needle must be directly beneath the shuttle tip.
  • Page 12 2 mm – Turn the handwheel in the direction of rotation until the shuttle tip extends 2 mm beyond the right-hand side of the needle. CAUTION: Care must be taken that the driver touches the shuttle in the direction of rotation. –...

  • Page 13: Synchronizing The Shuttle And Needle Bar Movements

    3.2 Synchronizing the shuttle and needle bar movements The movement of the shuttle is synchronized with that of the needle bar by means of the locking pin 1 and gauge 2. CAUTION: danger of injury Turn off the main switch. The shuttle and needle bar movements may only be synchronized with the main switch switched off.

  • Page 14: Shuttle-Tip/Needle Distance

    3.3 Shuttle-tip/needle distance The shuttle tip 9 must be as close as possible to the groove of the needle without touching it. CAUTION: danger of injury Turn off the main switch. The shuttle-tip/needle distance may only be adjusted with the main switch turned off.

  • Page 15: Driver/Needle Distance

    3.4 Driver/needle distance The oscillating driver 3 moves the shuttle 1 in the shuttle track. When the setting of the driver is correct it also acts as a needle guide in the vertical dimension. This avoids needle “flutter”, which causes dropped stitches. The right-hand side of the needle must be parallel to the driver 3 and at a very small distance from it.
  • Page 16 Adjustment: – Fold the upper part of the machine aside. – Undo locking screws 6. – Undo locking screws 8 on adjustment ring 9. – Extract driver with driver shaft 7 forwards from the shuttle-track support 10. – Once the driver shaft 7 has been dismantled, remove or add shims 12.

  • Page 17: Loop Stroke

    3.5 Loop stroke The loop stroke is the travel of the needle bar from its BDC point to the point at which the shuttle tip 9 is at the same level as the right-hand side of the needle. The loop stroke must be 4 mm. It is set with the gauge 1 (order no.

  • Page 18: Bobbin Ejector

    4. Bobbin ejector The ejector 4 must reliably eject the bobbin. The ejector tip must not enter the bobbin’s area of movement. CAUTION: danger of injury Turn off the main switch. The ejector may only be adjusted with the main switch turned off. –...

  • Page 19: Disc Cam

    5. Disc cam The cam tracks on the inside and outside of the disc cam determine the transport movement of the clamps. The inner and outer cam tracks control the longitudinal and transverse movement of the clamps respectively. The position of disc cam on the shaft determines clamp-transport timing.
  • Page 20 Worm-gear set When converting to a disc cam 4 with a different number of stitches the appropriate worm-gear set must also be fitted. A worm-gear set consists of worm drive 2 and worm screw 3. Intermediate transmission Fitting the intermediate transmission 6 with idler gear 5 doubles the number of stitches per disc-cam rotation (transmission ratio 2:1).

  • Page 21: Replacing The Disc Cam

    5.1 Replacing the disc cam CAUTION: danger of injury Turn off the main switch. The disc cam may only be replaced with the main switch turned off. Removing the material clamps and table plate – Remove the material clamps and table plate 1. Removing the disc-cam cover –...
  • Page 22 Fitting new disc cam – Fit the new disc cam. CAUTION: Ensure that the drive lever 9 for the longitudinal clamp movement engages in the inner cam track of the disc cam. The claw 11 must exactly fit the shaft edges 10. Remark: The illustration shows a machine with the intermediate transmission fitted.
  • Page 23 – Turn the handwheel in the direction of rotation until the clamps no longer move. At this moment, if the setting is correct, the needle is just about to penetrate the material. Adjustment: – Continue to turn the disc cam in the direction of rotation until the cam 12 is vertically above the shaft 13.

  • Page 24: Fitting The Intermediate Transmission

    5.2 Fitting the intermediate transmission Fitting the intermediate transmission 4 with idler gear 1 doubles the number of stitches per disc-cam rotation (transmission ratio 2:1). The intermediate transmission must be fitted before the new disc cam is installed. CAUTION: danger of injury Turn off the main switch.

  • Page 25: Replacing The Worm-Gear Pair And Worm Screw

    5.3 Replacing the worm-gear pair and worm screw 5.3.1 Fit/Remove the synchronous motor CAUTION: danger of injury Turn off the main switch. The synchronous motor may only be replaced with the main switch turned off. – Remove proximity switch 4. –...
  • Page 26 – Loosen the screw of the pulley 8 and separate the pulley from the motor shaft. – Loosen the mounting screws 9 and remove carefully the motor 10 from the fixing plate 11. Fitting the synchronous motor – Fit the synchronous motor 10, pulley 8 and the belt again.

  • Page 27: Replacing The Worm-Gear Pair And Worm Screw

    5.3.2 Replacing the worm-gear pair and worm screw CAUTION: danger of injury Turn off the main switch. The worm-gear pair and worm screw may only be replaced with the main switch turned off. CAUTION: Danger of breakage It is essential to remove the clamps and needle before replacing the worm-gear pair and worm screw.

  • Page 28: Worm-Screw Wheel Play

    – Undo locking screws 16. – Pull the handwheel 17 with belt pulley off the arm shaft. – Undo locking screws 22 on the bearing collar 19. The locking screws 22 are accessible through the slot 21. – Undo and remove screws 23 on bearing 20. The fixing screws 23 also act as extractor screws for the bearing.
  • Page 30 5.4 Worm-gear play There must be as little as possible gear play between the worm screw 11 and worm gear. CAUTION: danger of injury Turn off the main switch. The worm-gear play may only be adjusted with the main switch turned off.

  • Page 31: Shut-Down Devices

    6. Shut-down devices 6.1 Basic stop position (switch S7) Each disc cam (number of stitches) has its own cam 2 with a particular diameter. The diameter is such that switch S7 is not operated by the cam one stitch before or after the initial position. If the cam is replaced by another with a larger diameter (e.g.
  • Page 32 Setting switch S7 – Loosen screws 1 slightly. Push switch S7 upwards so that cam 2 reaches the switch sooner. – – Tighten screws 1. The outgoing flank of the 1st position must not coincide with the incoming flank of switch S7. Adjust switch S7 as described above for cam 2.

  • Page 33: Clamps And Table Plate

    7. Clamps and table plate 7.1 Position of table plate with respect to the needle The transmission of the movement from the disc cam to the clamps and the table plate is effected by lever systems. Within certain limits seam-type sizes can be altered by changing the lever transmission ratios.
  • Page 34 Aligning the table plate a) Transverse: – Turn the handwheel to lower the needle. – Turn the disc cam in the direction of rotation until one side of the table plate (in the transverse direction) reaches the needle. – Undo nuts 5 and 7. –...
  • Page 35 Setting the extent of the movement of the table plate 1: In the transverse direction: – Slightly undo nut 8. – Set the extent of the movement in the transverse direction by moving the crank along the slot. – Tighten nut 8. In the longitudinal direction: –...

  • Page 36: Position Of Clamps With Respect To The Table Plate

    7.2 Position of clamps with respect to the table plate The clamps 2 must be symmetrically aligned with the hole 1 in the table plate 3. CAUTION: danger of injury Turn off the main switch. Clamps may only be aligned with the main switch turned off. –...

  • Page 37: Thread Advance

    8. Thread advance To ensure that the seam is properly started a certain length of upper thread must be advanced. The advance takes place on completion of the previous seam with the clamps still lowered. Operational sequence – The upper-thread tensioner opens. –...

  • Page 38: Thread-Tensioning Spring

    9. Thread-tensioning spring Spring travel When the needle penetrates the material the thread-tensioning spring 1 must be in contact with the thread-tensioner support 6. When the eye of the needle enters the material the spring will then be just free of tension. Adjustment: –...

  • Page 39: Needle Cooling

    10. Needle cooling The needle cooling can be switched from normal to continuous operation. In normal operation needle cooling is only activated during sewing. The air stream emerging from the nozzle 2 must be pointed at the needle and be of adequate power. Adjustment: –...

  • Page 40: Thread-Burning Device

    11. Thread-burning device The electrical thread-burning device severs the upper and lower threads by burning them through. The end of the upper thread is fused. The resulting small hardenings prevent the seam from working loose. To ensure that the thread ends fuse properly it is essential to use only synthetic threads.
  • Page 41 Thread-extractor height With the thread lever in its highest position the thread extractor 3 should pass freely under the needle. – Place material 4 of the maximum permissible thickness (t = 16 mm) or a shim under the clamps. – Lower clamps.

  • Page 42: Upper Burning Device

    11.2 Upper burning device The correct lateral position of the burner with respect to the thread is automatically set when the burning device is secured. 11.2.1 Starting position The burner is in the starting position when the piston rod 4 of the cylinder 3 is fully retracted.

  • Page 43: Position Of Fully-Extended Burner

    11.2.2 Position of fully-extended burner When the setting is correct: – the fully-extended burner must be at a distance of approx. 1 mm from the clamped material – the fully-extended burner must be in contact with the thread positioned by the thread extractor and exert slight pressure on it. Both these requirements are met if the distance between the upper edge of the cylinder suspension and the lower edge of the attachment bracket is 120 mm.

  • Page 44: Adjusting The Burner Height-Stop

    11.2.3 Adjusting the burner height-stop – Place material 1 of the maximum permissible thickness (t = 16 mm) or a shim under the clamps. – Lower clamps. – Turn off the main switch. CAUTION: danger of injury Turn off the main switch. The burner height-stop may only be adjusted with the main switch turned off.

  • Page 45: Burner Angle

    11.2.4 Burner angle The burner 4 must be at an angle of approx. 90° to the thread positioned by the thread extractor 5. 90° CAUTION: danger of injury Turn off the main switch. The burner angle may only be adjusted with the main switch turned off. –...

  • Page 46: Lower Burning Device

    11.3 Lower burning device 11.3.1 Adjustment preconditions The setting of the lower burning device must be such that: – the surface 2 on the shuttle-track support 1 must be parallel to the throat plate.

  • Page 47: Distance Between Thread Extractor And Burner

    11.3.2 Distance between thread extractor and burner The distance between the thread extractor 2 and the burner 1 must be as small as possible in the front area. CAUTION: danger of injury Turn off the main switch. The distance between the thread extractor 2 and the burner 1 may only be adjusted with the main switch turned off.

  • Page 48: Burner Height

    11.3.4 Burner height When swivelled forwards the burner 1 exert slight pressure on the needle-hole sleeve 6. In the starting position the burner 1 must not touch any other part. CAUTION: danger of injury Turn off the main switch. The height of the burner 1 may only be adjusted with the main switch turned off.

  • Page 49: Thread-Suction Device

    12. Thread-suction device The thread-suction device 1 picks up the needle thread and holds it fast at the beginning of the seam. This prevents the needle thread from slipping out of the needle when sewing begins. CAUTION: danger of injury Turn off the main switch.

  • Page 50: Bobbin-Winder Adjustment

    13. Bobbin-winder adjustment The setting of the spring 1 of the thread layer 4 must be such that the thread layer switches off when the bobbin is full. The thread to be wound on should be tightly pre-tensioned. Adjust the two tensioners 5 accordingly.

  • Page 51: V-Belt Tension

    14. V-belt tension CAUTION: danger of injury Turn off the main switch. The V-belt tension may only be adjusted with the main switch turned off. – Remove proximity switch 4. – Remove handwheel 2. – Unplug connector 3. – Remove cover 1. –...

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