Duerkopp Adler 559 Service Instructions Manual
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Duerkopp Adler 559 Service Instructions Manual

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See also: Instruction and Installation Manual
Doppelkettenstich Knopflochautomat
Einfachkettenstich Schnürlochautomat
Automatic double-chainstitch buttonholer
Automatic single-chainstitch eyelet machine
Aufstellanleitung / Installation Instructions
Postfach 17 03 51, D-33703 Bielefeld Ÿ Potsdamer Straße 190, D-33719 Bielefeld
Telefon +49 (0) 5 21/ 9 25-00 Ÿ Telefax +49 (0) 5 21/ 9 25 24 35 Ÿ www.duerkopp-adler.com
Ausgabe / Edition:
Änderungsindex
07/2007
Rev. index: 01.0
Bedienanleitung / Operating Instructions
Serviceanleitung /
Printed in Federal Republic of Germany
559
Service Instructions
1
2
3
Teile-Nr./Part.-No.:
0791 559001

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  • Page 1 Doppelkettenstich Knopflochautomat Einfachkettenstich Schnürlochautomat Automatic double-chainstitch buttonholer Automatic single-chainstitch eyelet machine Bedienanleitung / Operating Instructions Aufstellanleitung / Installation Instructions Serviceanleitung / Service Instructions Postfach 17 03 51, D-33703 Bielefeld Ÿ Potsdamer Straße 190, D-33719 Bielefeld Telefon +49 (0) 5 21/ 9 25-00 Ÿ Telefax +49 (0) 5 21/ 9 25 24 35 Ÿ www.duerkopp-adler.com Ausgabe / Edition: Änderungsindex Teile-Nr./Part.-No.:...
  • Page 2 Anleitung, komplett / Manual, complete Übersicht Summary Bedienanleitung Operating Instructions Aufstellanleitung Installation Instructions Serviceanleitung Service Instructions Bauschaltplan Interconnection-diagram 9890 580001 B 9890 580001 B Pneumatikgeräteplan Pneumatic circuit plan 9770 559001 9770 559001 Alle Rechte vorbehalten. Eigentum der Dürkopp Adler AG und urheberrechtlich geschützt. Jede, auch auszugsweise Wiederverwendung dieser Inhalte ist ohne vorheriges schriftliches Einverständnis der Dürkopp Adler AG verboten.
  • 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

    Index Page: Part 3: Service Instructions Class 559 General notes Necessary program setting ........Adjusting the locking positions General notes .
  • Page 6 Index Page: Looper height ..........Adjusting the looping stroke .

  • Page 7: General Notes

    General notes The service manual on hand describes the adjustment of the automatic buttonholer 559 in an appropriate sequence. ATTENTION ! Various setting positions are interdependent. Therefore it is absolutely necessary to make the individual adjustments following the described order. The operations described in this service manual must only be executed by qualified staff or correspondingly instructed persons respectively! Caution: Danger of breakage !

  • Page 8: Adjusting The Locking Positions

    Adjusting the locking positions General notes With the help of the locking positions an easy adjustment of the needle motion to the looper and spreader motions is possible. When the arm shaft is in staking-out position, the rotary thread take-up disc and the eccentrics for the spreaders, the loopers and the connecting stitch have to be in staking-out position, too.

  • Page 9: Looper And Spreader Eccentric

    Looper and spreader eccentric Caution: Danger of injury! Switch the main switch off. Adjust the eccentrics only with the sewing machine switched off. Standard checking When the arm shaft is staked out with arresting pin 1, it should be possible to stake out the looper eccentric 3 and the spreader eccentric 4, too.

  • Page 10: Rotary Thread Take-Up Disc

    Rotary Thread Take-up Disc Caution: Danger of injury! Switch the main switch off. Adjust the rotary thread take-up disc only with the sewing machine switched off. Standard checking When the arm shaft has been arrested through the arresting pin 2, so that the looper holder is in the left end position (left entry point), the rotary thread take-up disc 6 should be in the right position for a needle 4 that is put on the bore hole of the rotary thread take-up...

  • Page 11: Throw Eccentric

    Throw eccentric Caution: Danger of injury ! Switch the main switch off. Adjust the rotary thread take-up disc only with the machine switched off. Standard checking When the looper turret 5 is in its right end position (right entry point), the arresting pin 4 inserted in the eccentric 2 should abut in the notching 1 at the arm.

  • Page 12: Needle Bar Positioning

    Needle bar positioning Caution: Danger of injury! Exercise utmost caution when making adjustments with the machine running. Standard checking When the machine positions automatically after being switched on, the needle bar must be in the top dead center. The looper turret is in its right end position (right entry point) then.

  • Page 13: Aligning The Looper Turret

    Aligning the looper turret Caution: Danger of injury! Switch the main switch off. Align the looper turret only with the machine switched off. Note Please observe the necessary program setting as described in chapter 1.1. Standard checking When the machine has reached its initial position after switching on the main switch, it must be possible to stake out the looper turret 2 with the arresting pin 1.

  • Page 15: Aligning The Needle Bar Parallel To The Looper Turret

    Aligning the needle bar parallel to the looper turret Caution: Danger of injury! Switch the main switch off. Adjust the needle bar only with the main switch switched off. Standard checking The needle bar 1 and the looper turret 3 must be in parallel position. –...

  • Page 17: Transversal Motion Of The Fabric Support Plate

    Transversal motion of the fabric support plate Caution: Danger of injury! Exercise utmost caution when making adjustments with the machine running. Note Please observe the necessary program setting as described in chapter 1.1. Standard checking The looper turret 3 must be in the center of the fabric support plate 4. When the automatic buttonholer is in reference position, the dimensions X1 and X2 must be equal when the fabric support plate is adjusted correctly.
  • Page 18 Correction – Switch the machine on and press the keys “P” and “ß” on the control panel simultaneously. – Enter code “2548”. – Press key ”OK”. The control switches to the technician level. – Select the menu “603” with the key “+”. In this mode the step motors are dead.

  • Page 19: Longitudinal Motion Of The Fabric Support Plate

    Longitudinal motion of the fabric support plate Caution: Danger of injury! Exercise utmost caution when making adjustments with the machine running. Note Please observe the necessary program setting as described in chapter 1.1. Standard checking When the machine is in reference position, the distance between the edge 3 of the fabric support plate 2 and the front edge 1 of the throat plate support should amount to approx.
  • Page 20 Correction – Switch the machine on and press the keys “P” and “ß” on the control panel simultaneously. – Enter code “2548”. – Press key ”OK”. The control switches to the technician level. – Select the menu “603”with the key “+”. In this mode the step motors are dead.

  • Page 21: Clamping Plates

    Clamping plates Inserted clamping plates ô Caution: Danger of injury! Switch the main switch off. Adjust the clamping plates only with the machine switched off. Standard checking The inserted clamping plates 1 and 2 should be in the holding groove 4 of the fabric support plate in parallel position and without clearance.

  • Page 22: Aligning The Clamping Plates As To The Fabric Support Plate

    Aligning the clamping plates Caution: Danger of injury! Switch the main switch off. Adjust the clamping plates only with the machine switched off. Standard checking Both clamping plates 3 must be adjusted in such a way that the distance between clamping plate and fabric support plate 1 is equal everywhere (distance X1 = distance X2).

  • Page 23: Adjusting The Spreading

    Adjusting the spreading Caution: Danger of injury! Exercise utmost caution when making adjustments with the machine running. Standard checking The distance X between the clamping plates 2 and the fabric support plate 1 should amount to 1.3 mm (non-spreaded) and to 0.3 mm (spreaded).
  • Page 24 Correction clamping plate – Switch the machine on. – Press the keys “P” and “F” on the control panel simultaneously. – Enter code “2548”. – Press key ”OK”. The control switches to the technician level. – Select the menu “601” with the key “+”. –...

  • Page 25: Height Of The Fabric Clamps

    8.4 Height of the fabric clamps Ø 12 mm Caution: Danger of injury! Switch the main switch off. Adjust the fabric clamp height only with the machine switched off. Standard checking The distance between the open fabric clamps 2 and 3 should amount to 12 mm.

  • Page 26: Adjusting The Locking Sheet

    Adjusting the locking sheet Caution: Danger of injury! Switch the main switch off. Adjust the locking sheets only with the machine switched off. Standard checking The locking sheets 1 must be adjusted in such a way that the stops 3 of the clamping plates abut centrally and as tight as possible.

  • Page 27: Arrest Of The Clamping Plates

    Arrest of the clamping plates Caution: Danger of injury! Exercise utmost caution when making adjustments with the machine running. Standard checking There must be a minimum clearance in the height of the inserted clamping plates 2 when: · no material is loaded ·...

  • Page 28: Adjusting The Fabric Clamping Pressure

    Adjusting the fabric clamping pressure Caution: Danger of injury! Switch the main switch off. Adjust the fabric clamping pressure only with the machine switched off. Standard checking The clamping pressure should be adjusted in such a way that the sewing material is clamped safely and tightly. Please observe that the sewing material is not damaged by a too high pressure.

  • Page 29: Adjusting The Seam Width

    Adjusting the seam width Presetting the seam width Caution: Danger of injury! Switch the main switch off. Adjust the seam width only with the machine switched off. Standard You can choose among two seam widths: · Seam width “Narrow” = Lever 2 mounted in position B ·...
  • Page 30 Setting the sewing equipment – Press the keys “P” and “F” of the control panel simultaneously. – Enter code “2548”. – Press the “OK” key. The control switches to the technician level. – Select the menu “500" (configuration automatic buttonholer). –...
  • Page 31 Notes:...

  • Page 32: Needle Zero Position

    Needle zero position Caution: Danger of injury! Switch the main switch off. Set the needle zero position only with the machine switched off. Standard checking The needle bar oscillates unidirectionally from the left (inside) to the right (outside). The needle zero position is on the left (inside). With the needle zero position the inner stitches of the forward and backward lip must be in a line.

  • Page 33: Cutting Knife (Eyelet Knife)

    10. Cutting knife (Eyelet knife) 10.1 Position of the cutting knife Caution: Danger of injury ! Switch the main switch off. Adjust the cutting knife only with the machine switched off. Standard checking In case of automates for “cutting after sewing” the cutting knife 2 should cut exactly between the seam rows and in the center of the eyelet (see illustration a).
  • Page 34 The cutting knife has to be adjusted in such a way that it cuts in the center of the sewn buttonhole shape. – Insert the cutting block. – Insert a short needle. – Load a piece of paper or cardboard as sewing material. –...

  • Page 35: Adjusting The Knife Parallel To The Cutting Block

    10.2 Adjusting the knife parallel to the cutting block – Loosen screws 1, 2 and 3. – Put the key 4 (in the accessories) on the hexagonal bolt 5 and twist it. – Push the cutting block 6 downward.

  • Page 36: Cutting Block Adjustment

    10.3 Cutting block adjustment Caution: Danger of injury ! Switch the main switch off. Adjust the cutting block only with the machine switched off. The cutting length can be altered by changing the cutting block. The cutting length is determined by the cutting block length. Standard checking The cutting block 3 must be in parallel position to the cutting knife 4.

  • Page 37: Adjusting The Switch For The Trimming System

    10.4 Adjusting the switch for the trimming system Caution: Danger of injury ! Switch the main switch off. Adjust the trimming system only with the machine switched off. Standard checking Before the fabric support plate continues transporting the fabric, the cutting stamp must be in its upper position.

  • Page 38: Cutting Pressure

    10.5 Cutting pressure Standard checking The cutting pressure is adjustable in order to keep the strain of all components as low as possible and to increase the durability of the cutting knife. According to the sewing material and the material thickness the cutting pressure should be adjusted as low as possible.

  • Page 39: Looper Height

    11. Looper height Before adjusting the looping stroke as well as the needle bar height and particularly after needle breakage it is necessary to check the correct looper height. Use gauge 2 for checking the looper height. Caution: Danger of injury ! Switch the main switch off.

  • Page 40: Adjusting The Looping Stroke

    12. Adjusting the looping stroke Caution: Danger of injury ! Switch the main switch off. Adjust the looping stroke only with the machine switched off. Standard checking The looping stroke is the way of the needle bar from its lowest position up to the point where the left or right looper tip is at the level of the middle of the needle.
  • Page 41 Correction Shift the clamping rings 3 and 4 in such a way that both looper points have the same distance to the needle. Adjust the left looper 8 and the right looper 7 so that both looper points in looping stroke position have the same position (X) to the needle. That means both looper points must be at an equal distance either before or behind the needle.

  • Page 42: Needle Bar Height

    13. Needle bar height Caution: Danger of injury ! Switch the main switch off. Adjust the needle bars only with the machine switched off. Standard checking The needle bar has to be adjusted in such a way that approx. ¾ of the needle’s eye 6 is to be seen under the left looper point when the needle bar has moved upward by 2.5 mm from the looping stroke position.

  • Page 43: Distance Between Looper And Needle

    14. Distance between looper and needle Caution: Danger of injury ! Switch the main switch off. Adjust the needle protection only with the machine switched off. Standard checking The looper points 1 and 4 should be in a distance of max. 0.1 mm to the needle 3.

  • Page 44: Needle Guard

    15. Needle guard Caution: Danger of injury ! Switch the main switch off. Adjust the needle guard only with the machine switched off. Standard checking The needle 1 must slightly abut on the needle guard 2 until the looper point have reached the needle. The distance between looper and needle must amount to 0.1 mm.

  • Page 45: Spreader

    16. Spreader Caution: Danger of injury ! Switch the main switch off. Adjust the spreader only with the machine switched off. Standard checking The distance between the fork spreader 5 and the left looper 4 must correspond to the thickness of the looper thread used (see illustration X opposite).

  • Page 46: Spreader Plate

    17. Spreader plate Caution: Danger of injury ! Switch the main switch off. Adjust the spreader plate only with the machine switched off. Standard checking The opening and closing of the spreaders is effected by the alternate motion of the spreader plate 2. When the needle bar is in the bottom dead center for the right stitch, the distance between spreader plate 2 and spreader shank 1 must be exactly the same as that between spreader plate 2 and spreader shank...

  • Page 47: Throat Plate

    18. Throat plate Caution: Danger of injury ! Switch the main switch off. Adjust the throat plate only with the machine switched off. Standard checking The needle should penetrate the needle hole of the throat plate on one side at the edge 1. The throat plate has to be positioned as highly as possible.

  • Page 48: Adjusting The Needle Thread Knife

    19. Adjusting the needle thread knife Caution: Danger of injury ! Switch the main switch off. Adjust the needle thread knife only with the machine switched off. Standard checking The cutting motion of the needle thread knife 2 is effected after sewing. The exact cutting moment is fixed in the control.
  • Page 49 Correction of the knife motion – Loosen the counter-nuts 5 and 8. – Adjust the stop screws 6 and 7 according to the rule. – Tighten the counter-nuts 5 and 8. Adjusting the height of the knife – Loosen screw 10. –...

  • Page 50: Adjusting The Fabric Clamps

    20. Adjusting the fabric clamps Caution: Danger of injury ! Switch the main switch off. Adjust the fabric clamps only with the machine switched off. Standard checking Between the needle 2 and the upper fabric clamp 1 there should be a distance of 1 mm over the whole length and in the eyelet.

  • Page 51: Thread Controller Spring

    21. Thread controller spring Caution: Danger of injury ! Switch the main switch off. Adjust the thread controller spring only with the machine switched off. Standard checking The thread controller spring 1 must hold the looper thread tensioned until the needle with the needle thread has accurately penetrated the triangle formed by the spreader.

  • Page 52: Maintenance

    22. Maintenance Caution: Danger of injury ! Switch the main switch off. Maintenance work of the automatic buttonholer must only be carried out with the machine switched off. The daily or weekly maintenance work (cleaning and oiling) to be carried out by the operators of the automatic buttonholer is described in Part 1: Operating Instructions.

  • Page 53: Annex

    23. Annex 23.1 Adjusting operations without head cover When the head cover is taken off, the machine is secured against unintentional starting. If you want to operate the machine without head cover for adjusting purposes, the plug 2 can be put on the connecting cable 3. The plug is in the switch casing 1.

  • Page 54: Fuses In The Control Box

    23.2 Fuses in the control box The fuses 1 and 2 for the control are on the back of the control box. Only insert the fuses indicated in the circuit diagram. 23.3 Exchange of the control See: Part 2: Installation Instructions. ·...

  • Page 55: Service Menu (Technician Level)

    24. Service menu (technician level) In the service menu of the 559 various basic adjustments and test programs can be executed. 24.1 Activating the service menu – Press the keys “P” and “F” simultaneously on the control panel. A code query appears. –...

  • Page 56: List Of Menu And Submenu Items

    24.5 List of menu and submenu items Menu item Description Configuration automatic buttonholer Loading position Throw width Thread monitor Duty cycle of the cutting block Sewing equipment Tension data for the needle thread calibration Value 1 Value 2 Value 3 Value 4 Value 5 Value 6...

  • Page 57: Menu Items 500 (Configuration Automatic Buttonholer)

    24.6 Menu items 500 (Configuration automatic buttonholer) 24.6.1 Menu item 501 (Loading position) Via this menu item the desired loading position can be set. Input: 0 … 68 (mm) Standard: 68 The value entered corresponds to the distance from the cutting point. The value “0”...

  • Page 58: Menu Items 520 (Tension Data For The Needle Thread Calibration)

    24.6.5 Menu item 511 (Sewing equipment) Various sewing equipment can be used with the automatic buttonholer 559. The selected sewing equipment is entered via this menu item. Input: 1501, 1502, 1504, 1521, 1522, 1524, 1551, 1553 or 1573, 1590, 1595. –...
  • Page 59 24.8.3 Menu item 553 (Brightness of the display) In this menu the brightness of the display is set. The set value means: Input: 0 … 3 Standard: 2 – Quit the menu item with key “ESC”. 24.8.4 Menu item 554 (Keyboard signal) In this menu the keyboard signal is switched on and off.

  • Page 60: Menu Items 600 (Multitest)

    24.9 Menu item 600 (Multitest) 24.9.1 Menu item 601 (output test) Attention: Danger of breakage ! The switching of output elements can lead to collisions with other machine elements as well as to damages to the automatic buttonholer. Before switching on an output element make sure that this cannot collide with other components.
  • Page 61 24.9.2 Menu item 602 (manual input test) Caution: Danger of injury! Exercise utmost caution when making the input test with the machine running. In this menu individual input elements can be tested. – Select the desired input element with the keys “ñ” or “ò”. The current status is indicated in the display: = input inactive = input active...
  • Page 62 24.9.4 Menu item 604 (sewing motor test) With this menu item the sewing motor can be checked. During the test the speed can be increased in steps of 100. Caution: Danger of breakage ! Before starting the sewing motor test remove the clamping plates in any case.
  • Page 63 24.9.6 Menu item 606 (ROM or flash test) In this menu item the read-only memory (ROM) and the flash memory are checked. Display: on the left: Calculated checksum on the right: 1 = Memory OK 0 = Memory not OK –...
  • Page 64 24.9.10 Menu item 610 (Checking the setting of the sewing instruments) In this menu item the settings of the sewing instruments can be checked. In order to do so, the sewing motor drives to the staking-out position UDC (Upper Dead Center) for calibration and then to the different positions for the checking of the looping stroke, needle stroke, needle guard and spreader position Caution: Danger of injury !
  • Page 65 – Press the “OK” key. The sewing motor drives to testing position 2 (left looping stroke). The display reads: 6 1 0 – Check, whether the tip of the left looper 2 points to the middle of the needle. If the looper’s position needs adjustment, proceed as follows: –...
  • Page 66 – Adjust the looper’s position. – Put the sewing machine down. – Press the “OK” key. The sewing motor drives back to testing position 2. – Check the looper’s position. – Press the “OK” key. The sewing motor drives to testing position 3 (right looping stroke). The display reads: 6 1 0 –...
  • Page 67 24.9.9 Menu item 611 (Breakpoint) With the aid of the testing program, the switching order of the valves can be checked. This testing program is particularly helpful for the setting of the thread catcher and the thread trimming systems because one can see precisely how the individual components lie in regard to the needle thread, looper thread and the gimp.

  • Page 68: Error Messages

    25. Error messages Error Info/Description Remedy Sewing motor timeout · Replace the cable 1051 · Cable to the sewing motor reference switch faulty · Reference switch defective · Replace the reference switch 1052 Sewing motor excess current · Cable of sewing motor faulty ·...
  • Page 69 Error Info/Description Remedy 2155 · Step motor X-axis · Eliminate the blocking/rough overcharge running · Step motor X-axis · Replace step motor X-axis blocked/moves too heavy · Replace the control · Step motor X-axis defective · Control defective 2156 · Step motor X-axis ·...
  • Page 70 Error Info/Description Remedy 2301 · Step motor Z-axis · Replace the cable timeout reference · Replace the reference switch · Cable to the reference switch faulty ·Reference switch defective 2302 · Step motor Z-axis · Eliminate the blocking Current supply fault ·...
  • Page 71 Error Info/Description Remedy 3300 · Fault in the machine control · Switch the machine off and on · Internal fault again 3724 · Software update · Inform DA-Service 4460 · Operation BF-4 · Switch the machine off and on · Malfunction again 4468 ·...
  • Page 72 Error Info/Description Remedy 8251 · ADSP Boot / · Switch the machine off and on 8255 Boot failure again · Internal fault · Software update · Inform DA-Service 8252 · Boot failure · Switch the machine off and on · Malfunction again 8254 8256...

  • Page 73: Troubleshooting

    26. Troubleshooting Caution: Danger of injury! Exercise utmost caution when eliminating defects with the machine switched on. Description of fault Possible cause Error elimination The display shows a message indicating the possible cause. The automate does not start up. Display: Info 200 Turn the handwheel in the direction Before sewing start the needle of rotation so that the needle is in...
  • Page 74 Description of fault Possible cause Error elimination Skipped stitches The material is not spread or Check the spreading spread too little. (see chapter “Spreading”). The matching needle size has Change the needle size. to be chosen according to the (See Operating Instructions) material, the material thickness Attention! and the thread used.
  • Page 75 Description of fault Possible cause Error elimination Thread breakage Thread-guiding parts as e.g. Check whether thread-guiding parts thread pipes, thread guides or are sharp-edged. the rotary thread take-up disc have sharp edges. Check whether the throat plate, Have the parts reworked by the the loopers or the spreaders service personnel.
  • Page 76 Description of fault Possible cause Error elimination Needle breakage The needle size is unsuitable Change the needle size. for the material or the thread. The needle hits the fabric Check the subclass on the control clamps panel. When changing the seam width Set the upper fabric clamps apart as the upper fabric clamps have far as required.
  • Page 77 Description of fault Possible cause Error elimination Faulty rotation of the sewing Possible rough running of Check all components belonging to works individual components the sewing works rotation. If neither faulty components nor rough running are found, the problem can in some cases be solved by altering the following parameters: - Speed reduction...

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