Dürkopp Adler 650-10 Operating instructions

650-10
Service Instructions

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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 2016
IMPORTANT
READ CAREFULLY BEFORE USE
KEEP FOR FUTURE REFERENCE

Table of Contents
Service Instructions 650-10 - 01.0 - 08/2016 1
1 About these instructions ...........................................................5
1.1 For whom are these instructions intended?..................................5
1.2 Representation conventions – symbols and characters...............5
1.3 Other documents..........................................................................6
1.4 Liability..........................................................................................6
2 Safety...........................................................................................9
2.1 Basic safety instructions...............................................................9
2.2 Signal words and symbols used in warnings..............................10
3 Individual settings....................................................................13
3.1 Laying the cables........................................................................13
3.2 Loosen screws in safety covers..................................................14
3.3 Removing the covers..................................................................14
3.3.1 Tilting and re-erecting the machine head...................................14
3.3.2 Removing and re-fitting the head cover......................................15
3.3.3 Removing and re-fitting the rear arm cover................................16
3.3.4 Removing and re-fitting the sewing material support and
column cover ..............................................................................16
3.3.5 Removing and inserting the throat plate.....................................17
3.4 Flats on shafts ............................................................................18
3.5 Locking the machine in place.....................................................19
3.6 Adjusting hook and needle bar...................................................20
3.7 Setting loop stroke and hook clearance .....................................22
3.8 Setting the needle bar height......................................................23
3.9 Setting the thread passage on the middle section holder...........24
3.10 Setting the throat plate ...............................................................24
3.11 Adjusting the thread cutter..........................................................25
3.11.1 Setting the control cam...............................................................25
3.11.2 Replacing and setting the thread-pulling knife............................28
3.11.3 Changing the counter blade .......................................................28
3.12 Setting the counter-blade and cutting pressure..........................29
3.13 Setting the path of the thread-pulling knife.................................30
3.14 Set the middle foot......................................................................31
3.15 Adjusting the toothed belt...........................................................32
3.15.1 Toothed belt between upper and lower shaft .............................32
3.15.2 Toothed belt for hook drive.........................................................33
3.16 Replacing and setting the top conveyor belts.............................36
3.16.1 Replacing the top conveyor belts ...............................................36
3.16.2 Setting the top conveyor belts ....................................................37
3.17 Replacing and setting the bottom conveyor belts.......................39
3.17.1 Replacing the bottom conveyor belts .........................................39
3.17.2 Setting the bottom conveyor belts ..............................................40
3.18 Replacing the gear rims..............................................................41
3.19 Checking the sewing foot lifting gear..........................................42
3.20 Dismounting and fitting electric thread tensioner........................45
3.21 Change the thread tensioning spring..........................................48
3.22 Set the spring tension.................................................................50
3.23 Setting the spring travel..............................................................51
3.24 Setting the thread regulator........................................................51
3.25 Winder ........................................................................................53
3.25.1 Setting the filling quantity............................................................53

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2Service Instructions 650-10 - 01.0 - 08/2016
3.25.2 Setting the winder winding form .................................................54
3.25.3 Setting the winding tension.........................................................54
4 Service settings via software (OP3000)..................................55
4.1 Calling up the Technician level...................................................55
4.2 Menu items at the Technician level............................................56
4.3 Menu item Default Program .................................................60
4.4 Menu item Machine config. .................................................62
4.4.1 Start Tack .............................................................................62
4.4.2 End Tack .................................................................................62
4.4.3 Thread Trim ...........................................................................62
4.4.4 Speed ........................................................................................63
4.4.5 Stop Positions ....................................................................64
4.4.6 Foot ..........................................................................................64
4.4.7 Thr. Tens. .............................................................................65
4.4.8 Pedal ........................................................................................65
4.5 Menu item User config. .......................................................66
4.6 Menu item Service ..................................................................67
4.6.1 Multitest ...............................................................................67
4.6.2 Calibration ...........................................................................70
4.6.3 Reset ........................................................................................74
4.6.4 Data Transfer .......................................................................75
4.7 Performing a software update ....................................................75
4.8 Testing the functionality of the keys on the control panel...........76
4.9 Update machine software...........................................................77
5 Service settings via software (OP7000)..................................79
5.1 Calling up the Technician level...................................................79
5.2 Menu items at the Technician level............................................80
5.3 Menu item Default Program Parameters .........................84
5.4 Menu item Machine Configuration ....................................87
5.4.1 Backtack At Start/End .....................................................87
5.4.2 Thread Trimmer ....................................................................88
5.4.3 Speed ........................................................................................88
5.4.4 Stop Positions ....................................................................88
5.4.5 Foot ..........................................................................................89
5.5 Menu item User configuration ..........................................90
5.6 Menu item USB Operations ...................................................91
5.7 Menu item Calibration .........................................................92
5.7.1 Adjust Flat Sewing Top ...................................................92
5.7.2 Feet Difference Calibration ........................................93
5.7.3 Thread Tension Calibration ...........................................93
5.8 Menu item Reset Operations ..............................................95
5.8.1 Reset All ...............................................................................95
5.8.2 Reset Sewing Programs .....................................................96
5.9 Test Input / Output ..........................................................96
5.10 Performing a software update ....................................................96
5.11 Update machine software...........................................................97
6 Maintenance............................................................................103
6.1 Cleaning ...................................................................................104
6.2 Lubricating................................................................................105

Table of Contents
Service Instructions 650-10 - 01.0 - 08/2016 3
7 Decommissioning...................................................................107
8 Disposal...................................................................................109
9 Technical data.........................................................................111
10 Troubleshooting ..................................................................... 113
10.1 Customer Service.....................................................................113
10.2 Messages of the software.........................................................114
10.3 Errors in sewing process .......................................................... 126
11 Appendix .................................................................................129

Table of Contents
4Service Instructions 650-10 - 01.0 - 08/2016

About these instructions
Service Instructions 650-10 - 01.0 - 08/2016 5
1 About these instructions
These instructions for the 650-10 have been prepared with utmost care.
They contain information and notes intended to ensure long-term and re-
liable operation.
Should you notice any discrepancies or if you have improvement re-
quests,thenwewouldbe gladto receiveyour feedbackthroughCustomer
Service (p. 113).
Consider the instructions part of the product and store them in a place
where they are readily available.
1.1 For whom are these instructions intended?
These instructions are intended for:
• Specialists:
This group has the appropriate technical training for performing
maintenance or repairing malfunctions.
Operating Instructions are supplied separately.
With regard to minimum qualificationand other requirements to be met by
personnel, please also follow the chapter Safety (p. 9).
1.2 Representation conventions – symbols and characters
Variousinformationintheseinstructions isrepresentedorhighlightedbythe
following characters in order to facilitate easy and quick understanding:
Proper setting
Indicates proper setting.
Malfunctions
Specifies the faults that can occur due to an incorrect setting.
Cover
Specifies which covers have to be removed in order to access the compo-
nents to be set.
Steps to be performed when operating the machine (sewing and
equipping)
Steps to be performed for service, maintenance, and installation
Steps to be performed via the software control panel
The individual steps are numbered:
1. First step
2. Second step
The steps must always be followed in the specified order.
1.
2.
…

About these instructions
6Service Instructions 650-10 - 01.0 - 08/2016
Lists are marked by bullet points.
Result of performing an operation
Change on the machine or on the display/control panel.
Important
Special attention must be paid to this point when performing a step.
Information
Additional information, e.g. on alternative operating options.
Sequence
Specifies the work to be performed before or after a setting.
References
 Reference to another section in these instructions.
Safety Important warnings for the machine users are specially designated.
Since safety is of particular importance, hazard symbols, levels of
danger and their signal words are described separately in the chapter
Safety (p. 9).
Orientation If no other clear location markers are used in a diagram, indications of
right or left are always from the operator's point of view.
1.3 Other documents
The machine includes components from other manufacturers. Each man-
ufacturer has performed a hazard assessment for these purchased parts
and confirmed their design compliance with applicable European and na-
tional regulations. The proper use of these components is described in
each manufacturer's instructions.
1.4 Liability
Allinformationintheseinstructionswas compiledwith considerationtothe
state of the art, and applicable standards and regulations.
•


About these instructions
Service Instructions 650-10 - 01.0 - 08/2016 7
Dürkopp Adler cannot be held liable for damage resulting from:
• Breakage and damage during transport
• Failure to observe these instructions
• Improper use
• Unauthorized modifications to the machine
• Use of untrained personnel
• Use of unapproved replacement parts
Transport
Dürkopp Adler cannot be held liable forbreakage and transport damages.
Inspect the delivery immediately upon receiving it. Report any damage
to the last transport manager. This applies even if the packaging is
undamaged.
Leave machines, equipment and packaging material in the condition in
which they werefound whenthedamage wasdiscovered.This will ensure
any claims against the transport company.
Report all other complaints to Dürkopp Adler immediately after receiving
the product.

About these instructions
8Service Instructions 650-10 - 01.0 - 08/2016

Safety
Service Instructions 650-10 - 01.0 - 08/2016 9
2 Safety
This chapter contains basic information for your safety. Read the instruc-
tions carefully before setting up or operating the machine. Always follow
the information included in this section. Failure to do so can result in seri-
ous injury and property damage.
2.1 Basic safety instructions
The machine should only be used as described in this manual.
These instructions should be available at the machine’s location at all
times.
Work on live components and equipment is prohibited. Exceptions are
defined in the DIN VDE 0105.
For the following work, switch off the machine at the main switch or dis-
connect the power plug:
• Replacing the needle or other sewing tools
• Leaving the workstation
• Performing maintenance work and repairs
• Threading
Missingorfaultysparepartscouldimpairsafetyanddamagethemachine.
Only use original spare parts from the manufacturer.
Transport Use a sturdy lifting carriage or forklift truck for transporting the machine.
Raise the machine max. 20 mm and secure it to prevent it from slipping
off.
Setup The power cable must have a plugthat is authorized for use in the country
in which the machine is being used. The power plug may only be connect-
ed to the power cable by qualified specialists.
Obligations
of the operator Observe the country-specific safety and accident prevention regulations
and the legal regulations concerning industrial safety and the protection of
the environment.
Allthe warningsand safetysigns onthe machinemust alwaysbeinlegible
condition. Do not remove!
Missing or damaged warnings and safety signs must be replaced
immediately.
Requirements
to be met by
the personnel
Only qualified specialized staff may:
• set up the machine
• carry out maintenance work and repairs
• carry out work on electrical equipment
Only authorized persons may work on the machine and they must first
have understood these instructions.

Safety
10 Service Instructions 650-10 - 01.0 - 08/2016
Operation Inspect the machine while in use for any externally visible damage.
Stop working if you notice any changes to the machine. Report any
changes to your supervisor. Machines must no longer be used if they
are damaged.
Safety
equipment Safety equipment should not be removed or deactivated. If it is essential
to remove or deactivate safety equipment for a repair operation, it must be
refitted and put back into service immediately afterward.
2.2 Signal words and symbols used in warnings
Warnings in the text are distinguished by color bars. The color scheme
based on the severity of the danger. Signal words indicate the severity of
the danger.
Signal words Signal words and the hazard that they describe:
Symbols The following symbols indicate the type of danger to personnel:
Signal word Meaning
DANGER (with hazard symbol)
If ignored, fatal or serious injury will result
WARNING (with hazard symbol)
If ignored, fatal or serious injury can result
CAUTION (with hazard symbol)
If ignored, moderate or minor injury can result
CAUTION (with hazard symbol)
If ignored, environmental damage can result
NOTICE (without hazard symbol)
If ignored, property damage can result
Symbol Type of danger
General
Electric shock

Safety
Service Instructions 650-10 - 01.0 - 08/2016 11
Examples Examples of the layout of warnings in the text:
This is what a warning looks like for a hazard that will result in serious
injury or even death if ignored.
This is what a warning looks like for a hazard that could result in seri-
ous or even fatal injury if ignored.
This is what a warning looks like for a hazard that could result in
moderate or minor injury if the warning is ignored.
Puncturing
Crushing
Environmental damage
Symbol Type of danger
DANGER
Type and source of danger!
Consequences of non-compliance.
Measures for avoiding the danger.
WARNING
Type and source of danger!
Consequences of non-compliance.
Measures for avoiding the danger.
CAUTION
Type and source of danger!
Consequences of non-compliance.
Measures for avoiding the danger.

Safety
12 Service Instructions 650-10 - 01.0 - 08/2016
This is what a warning looks like for a hazard that could result in
environmental damage if ignored.
This is what a warning looks like for a hazard that could result in
property damage if ignored.
CAUTION
Type and source of danger!
Consequences of non-compliance.
Measures for avoiding the danger.
NOTICE
Type and source of danger!
Consequences of non-compliance.
Measures for avoiding the danger.

Individual settings
Service Instructions 650-10 - 01.0 - 08/2016 13
3 Individual settings
Always adhere to the specified sequence for the individual steps.
Always observe all information on requirements and following settings
marked at the side with .
3.1 Laying the cables
Ensure that all cables in the machine are laid in such a way that they do
not impair the function of the moving parts.
To lay the cables:
1. Lay any cable that is too long neatly in proper cable snakes.
2. Tie the snakes together using a cable tie.
If possible, bind the snakes to fixed parts.
NOTICE
Property damage due to incorrect sequence!
Failure to observe can result in damage to the machine.
It is essential to adhere to the working sequence specified in this
manual.
WARNING
Risk of injury from moving parts, cutting and
sharp parts!
Crushing, cutting and puncturing are possible.
Switch off the main switch.
If possible, only change settings when the machine
is switched off.
NOTICE
Property damage and malfunctions due to laying the cables
incorrectly!
Excess cabling may obstruct moving machine parts in their ability to
function correctly. This affects the sewing process and can result in
damage to the machine.
Lay excess cable as described above.

Individual settings
14 Service Instructions 650-10 - 01.0 - 08/2016
Important
The cables must be fixed in place!
3. Cut off any overlapping cable ties.
3.2 Loosen screws in safety covers
Screws used in safety covers must not be completely removed from the
screw hole.
1. As soon as the screws are loosened, remove the cover.
The screws can either remain in the housing or in the cover.
Such screws are identified in the text by the suffix
safety cover.
3.3 Removing the covers
For many types of setting work, you will have to remove the machine
covers in order to access the components.
Described here is how to remove the individual covers and how to refit
them. Just the covers that need to be removed is then specified in the text
for that particular type of setting work.
3.3.1 Tilting and re-erecting the machine head
To access the componentson the underside of the machine,swivel up the
machine head.
Fig. 1: Tilting and re-erecting the machine head
Tilting the machine head
To tilt the machine head:
1. Tilt the machine head (1) as far as it will go.
2. Loosen all five screws (3).
1
2
3
33
3
3
(1) - Machine head
(2) - Tray (3) - Screws

Individual settings
Service Instructions 650-10 - 01.0 - 08/2016 15
3. Remove the tray (2) downwards.
Erecting the machine head
To erect the machine head:
1. Fit the tray (2).
2. Tighten all 5 screws (3).
3. Erect the machine head (1).
3.3.2 Removing and re-fitting the head cover
Fig. 2: Removing and re-fitting the head cover
Dismounting the head cover
To dismount the head cover:
1. Loosen both screws (1).
2. Remove the head cover (2)
Fitting the head cover
To fit the head cover:
1. Fit the head cover (2).
2. Tighten both screws (1).
1
2
(1) - Screws (2) - Head cover

Individual settings
16 Service Instructions 650-10 - 01.0 - 08/2016
3.3.3 Removing and re-fitting the rear arm cover
Fig. 3: Removing and re-fitting the rear arm cover
Dismounting the rear arm cover
To dismount the rear arm cover:
1. Loosen all five screws (1) on the rear arm cover.
2. Remove the rear arm cover (2).
Fitting the rear arm cover
To fit the rear arm cover:
1. Fit the rear arm cover (2).
2. Tighten all five screws (1) on the rear arm cover.
3.3.4 Removing and re-fitting the sewing material support and
column cover
Fig. 4: Removing and fitting the sewing material support and column cover
1
2
(1) - Screws (2) - Rear arm cover
3
2
1
3
(1) - Screws
(2) - Column cover (3) - Sewing material support

Individual settings
Service Instructions 650-10 - 01.0 - 08/2016 17
Removing the sewing material support and column cover
To remove the sewing material support and column cover:
1. Loosen both screws (1).
2. Lift the sewing material support (3) slightly and remove it to the left.
3. Lift the column cover (2) slightly and remove it to the left.
Fitting the sewing material support and column cover
To fit the sewing material support and column cover:
1. Fit the column cover (2) from the top left.
2. Fit the sewing material support (3) from the top left.
3. Tighten both screws (1).
3.3.5 Removing and inserting the throat plate
Removing the throat plate
Fig. 5: Removing the throat plate
To remove the throat plate:
1. Remove the material support and column cover (p. 16).
2. Loosen the screws (4).
3. Remove the guide piece (3).
4. Remove the throat plate (7) upwards.
(1) - Pins
(2) - Middle section holder
(3) - Guide piece
(4) - Screws
(5) - Hook
(6) - Recess
(7) - Throat plate
②⑤
⑥⑦①
③ ④

Individual settings
18 Service Instructions 650-10 - 01.0 - 08/2016
Inserting the throat plate
Fig. 6: Inserting the throat plate
To insert the throat plate:
1. Insert the throat plate (7) from above.
2. Insert the guide piece (3) such that the pins (1) engage in the throat
plate(7) and the middle section holder (2) fits into the recess (6) for
the hook (5).
3. Tighten the guide piece (3) using the screws (4).
4. Fit the material support and column cover (p. 16).
3.4 Flats on shafts
Flats on shafts look like this:
Fig. 7: Flats on shafts
Some shafts have flat surfaces at the points where the components are
screwed on. This stabilizes the connection and makes adjustment easier.
Important
Always ensure that the screw faces are completely flush with the surface!
(1) - Pins
(2) - Middle section holder
(3) - Guide piece
(4) - Screws
(5) - Hook
(6) - Recess
(7) - Throat plate
②⑤
⑥⑦①
③ ④
2
1
(1) - Flat (2) - Shaft