Duerkopp Adler 506-3 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
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Ausgabe / Edition: Änderungsindex Teile-Nr./Part.-No.:
10/2008 Rev. index: 01.0 Printed in Federal Republic of Germany 0791 506011
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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.
Copyright © Dürkopp Adler AG - 2008

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.
The instruction manual is intended to complement existing national
accident prevention and environment protection regulations.
The instruction manual must always be available at the machine/sewing
unit.
The instruction manual must be read and applied by any person that is
authorized to work on the machine/sewing unit. This means:
–Operation, including equipping, troubleshooting during the work
cycle, removing of fabric waste,
–Service (maintenance, inspection, repair) and/or
–Transport.
The user also has to assure that only authorized personnel work on the
machine.
The user is obliged to check the machine at least once per shift for
apparent damages and to immediatly report any changes (including the
performance in service), which impair the safety.
The user company must ensure that the machine is only operated in
perfect working order.
Never remove or disable any safety devices.
If safety devices need to be removed for equipping, repairing or
maintaining, the safety devices must be remounted directly after
completion of the maintenance and repair work.
Unauthorized modification of the machine rules out liability of the
manufacturer for damage resulting from this.
Observe all safety and danger recommendations on the machine/unit!
The yellow-and-black striped surfaces designate permanend danger
areas, eg danger of squashing, cutting, shearing or collision.
Besides the recommendations in this instruction manual also observe
the general safety and accident prevention regulations!

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. Before putting into service also read the safety rules and
instructions of the motor supplier.
3. The machine must be used only for the purpose intended. Use of
the machine without the safety devices is not permitted. Observe all
the relevant safety regulations.
4. When gauge parts are exchanged (e.g. needle, presser foot, needle
plate, feed dog and bobbin) when threading, when the workplace is
left, and during service work, the machine must be disconnected
from the mains by switching off the master switch or disconnecting
the mains plug.
5. Daily servicing work must be carried out only by appropriately
trained persons.
6. Repairs, conversion and special maintenance work must only be
carried out by technicians or persons with appropriate training.
7. For service or repair work on pneumatic systems, disconnect the
machine from the compressed air supply system (max. 7-10 bar).
Before disconnecting, reduce the pressure of the maintenance unit.
Exceptions to this are only adjustments and functions checks made
by appropriately trained technicians.
8. Work on the electrical equipment must be carried out only by
electricians or appropriately trained persons.
9. Work on parts and systems under electric current is not permitted,
except as specified in regulations DIN VDE 0105.
10. Conversion or changes to the machine must be authorized by us
and made only in adherence to all safety regulations.
11. For repairs, only replacement parts approved by us must be used.
12. Commissioning of the sewing head is prohibited until such time as
the entire sewing unit is found to comply with EC directives.
13. The line cord should be equipped with a country-specific mains
plug. This work must be carried out by appropriately trained
technicians (see paragraph 8).
It is absolutely necessary to respect the safety
instructions marked by these signs.
Danger of bodily injuries !
Please note also the general safety instructions.

Contents Page:
Part 3: Service Instructions Cl. 506-3
1. General .................................................... 3
2. Removing the top cover and turning over the upper part of the machine
2.1 Removingthetopcover........................................... 4
2.2 Turning over the upper part of the machine ............................... 6
3. Shuttle, needle bar
3.1 Needle bar height............................................... 7
3.2 Synchronizing the shuttle and needle bar movements......................... 9
3.3 Shuttle-tip/needle distance ......................................... 10
3.4 Driver/needle distance ........................................... 11
3.5 Loop stroke .................................................. 13
4. Bobbin ejector ................................................ 14
5. Disc cam
5.1 Replacingthedisccam........................................... 17
5.2 Fittingtheintermediatetransmission................................... 20
5.3 Replacing the worm-gear pair and worm screw ............................. 21
5.3.1 Fit/Remove the synchronous motor .................................... 21
5.3.2 Replacing the worm-gear pair and worm screw ............................. 23
5.4 Worm-screw wheel play ........................................... 24
6. Shut-down devices
6.1 Basicstopposition(switchS7)....................................... 27
7. Clamps and table plate
7.1 Position of table plate with respect to the needle ............................ 29
7.2 Positionofclampswithrespecttothetableplate............................ 32
8. Thread advance ............................................... 33
9. Thread-tensioning spring ......................................... 34
10. Needle cooling ................................................ 35
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Contents Page:
11. Thread-burning device
11.1 Threadextractor ............................................... 36
11.2 Upper burning device ............................................ 38
11.2.1Startingposition................................................ 38
11.2.2 Position of fully-extended burner ..................................... 39
11.2.3Adjustingtheburnerheight-stop...................................... 40
11.2.4 Burner angle.................................................. 41
11.3 Lowerburningdevice ............................................ 42
11.3.1 Adjustment preconditions .......................................... 42
11.3.2Distancebetweenthreadextractorandburner............................. 43
11.3.3Positionofburnerwhenswivelledforwards............................... 43
11.3.4Burnerheight................................................. 44
11.3.5 Thread-extractor height ........................................... 44
12. Thread-suction device ........................................... 45
13. Bobbin-winder adjustment ........................................ 46
14. V-belt tension ................................................ 47
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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.
Danger of breakage
It is essential for the adjustments specified in these servicing
instructions to be carried out before the machine is recommissioned
following disassembly.
Never start the machine with the drive motor rotating in the wrong
direction.
A sewing run may not commence unless the head cover and the
shuttle-area cover are closed.
If either of these is open, all control functions are blocked.
CAUTION: danger of injury
Prior to all repair, modification and maintenance work the main switch
must be turned off and the machine disconnected from the
compressed-air supply.
Adjustment work and function testing carried out with the machine
running require the utmost care and observance of all safety
precautions.
Setting gauges
We can supply the following setting gauges on request:
Setting gauge Use Order No.
Gauge Loop-stroke adjustment 0981 150009
Calliper Loop-stroke adjustment 0981 150006
Gauge Adjusting the arm-shaft 7270 159160
eccentric (optional)
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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.
CAUTION: danger of injury
Turn off the main switch and disconnect the machine from the
compressed-air supply.
The arm cover must not be removed until both these steps have been
taken.
Swivelling the control unit aside
–Slightly undo Allen screws 5.
These are accessible through the holes 4 in the casing.
–Carefully swivel the control unit aside.
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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.
CAUTION :
The use of force to remove the arm cover may cause damage to the
compressed-air line.
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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
themainswitchisoff.
–Carefully turn over the upper part of the machine until it is
supported by the table-plate prop.
The underside of the upper part of the machine is now accessible
for service work.
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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.
CAUTION: danger of injury
Turn off the main switch.
The needle bar height may only be adjusted with the main switch
turned off.
–Turn off the main switch.
–Undo screws 2.
–Remove clamp 3.
CAUTION: Danger of breakage
It is essential for the clamps to be removed prior to the following
adjustment work.
This prevents the needle from fouling the clamps in the course of
subsequent adjustments.
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–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.
–Undo locking screws 4.
–Adjust the height of the needle bar so that the lower edge of the
shuttle tip just becomes visible in the eye of the needle.
–Fully tighten locking screws 4.
–Refasten clamp 3 with screws 2.
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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.
–Insert locking pin 1 in the hole in the housing of the upper part of the
machine.
–Turn the handwheel in the direction of rotation until the locking pin 1
perceptibly engages in the groove of the arm-shaft handle.
–Place the gauge 2 on the shaft between the worm-screw wheel 3 and the
eccentric 6 in such a way that the pin 4 points to the eccentric 6.
–Push the gauge against the eccentric.
The pin 4 must fit into the hole 5.
–The legs 8 of the gauge must lie flat on the unpainted surface of the arm.
Adjustment:
–Remove the top cover.
–Undo the locking screw 7 on the eccentric.
–Turn the handwheel until the pin 4 of the gauge fits into the hole 5
of the eccentric.
–Fully tighten locking screw 7.
–Replace cover.
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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.
–Turn the handwheel to bring the shuttle tip 9 close to the needle and check
the position of the shuttle tip with respect to the throat of the needle.
Adjustment:
–Fold the upper part of the machine aside.
–Undo locking screws 6.
–Undo locking screws 4 on adjustment ring 7.
–Extract driver with driver shaft 5 forwards from the shuttle-track
support 3.
–Undo locking screw 1 on the base plate.
–Slightly screw in pressure screw 2.
This opens the base-plate jaws.
–Bring the shuttle tip 8 close to the throat of the needle by axially
shifting the shuttle-track support 3.
The upper surface of the shuttle-track support 3 must be parallel to
the needle plate.
–Screw pressure screw 2 out again.
–Fully tighten locking screw 4 (max. 21 Nm).
–Replace driver with driver shaft 5 in the shuttle-track support 3 and
push back as far as it will go.
–Push adjustment ring 7 as far as it will go against the end of the
shuttle-track support 3.
–Fully tighten locking screws 4.
–Fully tighten locking screws 6.
CAUTION:
It is essential to check the loop-stroke setting.
Fitting a stronger needle has the effect of altering the distance
between the shuttle tip and the needle.
This shuttle-tip/needle distance must be corrected.
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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.
For this purpose the driver 3 must be brought close to the needle.
CAUTION: danger of injury
Turn off the main switch.
The driver/needle distance may only be adjusted with the main switch
turned off.
–Turn the handwheel to bring the needle to its highest point.
–Pull the sprung bolt 4 forwards to unlock the shuttle-track spring 5.
–Swivel back the shuttle-track spring 5.
–Remove plunger ring 2.
–Extract shuttle 1.
–To check the setting turn the handwheel to bring the driver 3 close
to the needle.
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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. The shims can be found in the accessory kit.
Hint
The use of a smaller needle normally requires a shim to be added
and vice versa.
–Replace driver with driver shaft 7 in the shuttle-track support 10
and push it back as far as it will go.
–Push adjustment ring 8 as far as it will go against the end of the
shuttle-track support 10.
–Fully tighten locking screws 8.
This prevents the driver from being axially shifted.
–Reset the loop stroke (see chapter 3.5).
–Check the setting by turning the belt pulley on the arm shaft. The
right-hand side of the needle must be parallel to the driver and at a
very small distance from it.
If the setting is not correct the adjustment process must be
repeated.
CAUTION:
After adjusting the driver/needle distance it is essential to readjust the
loop stroke as described in chapter 3.5.
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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. 0981 150012) and block 2
(order no. 0981 150006).
CAUTION: danger of injury
Turn off the main switch.
The loop stroke may only be adjusted with the main switch turned off.
–Turn the handwheel to bring the needle bar 4 to its lowest position.
–Open the cover.
–Press gauge 1 with block 2 upwards against the housing.
–Fully tighten locking screw 3 on block 2.
–Extract gauge 1.
–Turn handwheel in the direction of rotation until the block 2 is in
contact with the housing.
–Check whether the shuttle tip 9 is at the same level as the
right-hand side of the needle.
Adjustment:
–Fold the upper part of the machine aside.
–Undo locking screws 8.
–Twist the driver shaft 7 as required.
–Fully tighten locking screws 8.
–Check the driver/needle distance once again and correct it if
necessary (see chapter 3.4).
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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.
–Fold the upper part of the machine aside.
–Undo screw 1.
–Twist the ejector 4 on the axle so that the bobbin is reliably ejected
when lever 3 is pressed.
–Fully tighten screw 1.
–Test by pressing the ejector lever 3.
The bobbin case must automatically swivel out.
–Undo locknut on screw 2.
–Turn screw 2 to set the end position.
The ejector tip must not enter the bobbin’s area of movement.
–Fully tighten locknut on screw 2.
–Undo locknut on screw 5.
–Turn screw 5 to set the end position.
The ejector must reliably eject the bobbin.
–Fully tighten locknut on screw 5.
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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.
The disc cam is in its initial position when cam 1 is located immediately
in front of switch S7.
Disc cam
The various seam (stitch) types are determined by disc cams, which
are easy to replace.
All disc cams with the same stitch number are mutually
interchangeable.
The disc cams are numbered.
The numbers engraved on them have the following meaning:
Example: 116 - 072 .- 1
116 = number of stitches per
disc-cam rotation
072 = stitch type
1= calculation operation
When converting to a different seam type the clamps belonging to the
installed disc cam must be fitted.
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S7 1

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).
without intermediate transmission: 42, 58 and 72 stitches per
disc-cam rotation
(depending on the
worm-gear set)
with intermediate transmission: 84, 116 and 144 stitches per
disc-cam rotation
(depending on the
worm-gear set)
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