Duerkopp Adler 559 Operating instructions

559
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 Potsdamer Straße 190, D-33719 Bielefeld
Telefon [phone] Telefax+49(0)521/9252435www.duerkopp-adler.com
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Ausgabe / Edition: Änderungsindex Teile-Nr./Part.-No.:
07/2007 Rev. index: 01.0 Printed in Federal Republic of Germany 0791 559001

Anleitung, komplett / Manual, complete
559
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.
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 - 2007
Übersicht Summary
Bedienanleitung
Aufstellanleitung
Serviceanleitung
Bauschaltplan
9890 580001 B
Pneumatikgeräteplan
9770 559001
Operating Instructions
Installation Instructions
Service Instructions
Interconnection-diagram
9890 580001 B
Pneumatic circuit plan
9770 559001

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.

Index Page:
Part 3: Service Instructions Class 559
1. General notes
1.1 Necessaryprogramsetting ........................................ 3
2. Adjusting the locking positions
2.1 General notes ................................................ 4
2.2 Looper and spreader eccentric ...................................... 5
2.3 Rotarythreadtake-updisc ........................................ 6
2.4 Throweccentric ............................................... 7
3. Needle bar positioning .......................................... 8
4. Aligning the looper turret ........................................ 9
5. Aligning the needle bar parallel to the looper turret........................ 11
6. Transversal motion of the fabric support plate ........................... 13
7. Longitudinal motion of the fabric support plate .......................... 15
8. Clamping plates
8.1 Insertedclampingplates.......................................... 17
8.2 Aligning the clamping plates as to the fabric support plate...................... 18
8.3 Adjusting the spreading........................................... 19
8.4 Heightofthefabricclamps......................................... 21
8.5 Adjusting the locking sheet ........................................ 22
8.6 Arrestoftheclampingplates ....................................... 23
8.7 Adjustingthefabricclampingpressure ................................. 24
9. Adjusting the seam width
9.1 Presettingtheseamwidth......................................... 25
9.2 Needle zero position ............................................ 26
10. Cutting knife (Eyelet knife)
10.1 Positionofthecuttingknife ........................................ 29
10.2 Adjustingtheknifeparalleltothecuttingblock............................. 31
10.3 Cuttingblockadjustment.......................................... 32
10.4 Adjustingtheswitchforthetrimmingsystem.............................. 33
10.5 Cuttingpressure............................................... 34
10.6 Cuttingduration............................................... 34
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Index Page:
11. Looper height ................................................ 35
12. Adjusting the looping stroke ...................................... 36
13. Needle bar height.............................................. 38
14. Distance between looper and needle ................................. 39
15. Needle guard ................................................ 40
16. Spreader ................................................... 41
17. Spreader plate ............................................... 42
18. Throat plate ................................................. 43
19. Adjusting the needle thread knife ................................... 44
20. Adjusting the fabric clamps ....................................... 46
21. Thread controller spring ......................................... 47
22. Maintenance ................................................. 48
23. Annex
23.1 Adjusting operations without head cover ................................ 49
23.2 Fusesinthecontrolbox .......................................... 50
23.3 Exchange of the control .......................................... 50
24. Service menu (technician level)
24.1 Activatingtheservicemenu........................................ 51
24.2 Selectionofamenuitem/submenuitem................................. 51
24.3 Multitest.................................................... 51
24.4 Quittingtheservicemenu ......................................... 51
24.5 Listofmenuandsubmenuitems..................................... 52
24.6 Menu items 500 (Configuration automatic buttonholer) ........................ 53
24.7 Menu items 520 (Tension data for the needle thread calibration) .................. 54
24.7 Menu items 550 (Configuration operation) ............................... 54
24.8 Menuitems600(Multitest)......................................... 56
25. Error messages ............................................... 64
26. Troubleshooting .............................................. 69

1. 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 !
Before recommissioning of the automatic buttonholer after
disassembly operations first carry out the necessary adjustments
according to these service instructions.
Before all setting operations of parts involved in the stitch
formation:
–Insert a new needle without any damage.
Caution: Danger of injury !
In case of repair, alteration and maintenance work:
–Switchthemainswitchoff.
Exception:
Adjustments carried out with the help of test or adjusting programs.
Adjusting operations and function tests when the machine is
running
–Carry out adjusting operations and function tests of the running
machine only under observation of all safety measures and with
utmost caution.
Adjusting operation in the needle zone
–In order to avoid injuries remove the corresponding parts before
carrying out adjusting operations.
Exception:
The parts are absolutely necessary for the adjusting operations.
1.1 Necessary program setting
For adjusting the automatic buttonholer the following buttonhole shape
has to be set at the control panel:
–Buttonhole without bartack
–Connecting stitch = 0
–No cutting space
–Set the connecting stitch to “wide” (see chapter 9 “Setting the seam
width”)
Note!
The set seam width has to be checked not only mechanically but
also at the control panel!
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2. Adjusting the locking positions
2.1 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.
The positions have been set by the manufacturer in such a way that
standard material can be sewn with the 559.
If you want to use other needle sizes, thread sizes or materials, you
may have to set positions slightly differing from the staking-out
position.
The locking pegs are included in the accessories of the machine and
have a diameter of 5 mm.
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2.2 Looper and spreader eccentric
Caution: Danger of injury!
Switchthemainswitchoff.
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.
–Stake out the arm shaft with arresting pin 1.
Important !
In this position the needle bar must be in the top dead center in
front of the left entry point.
–Check with the arresting pin 2 whether the looper eccentric 5 and
the spreader eccentric 6 can be staked out.
Correction
–Stake out the arm shaft with the arresting pin 1.
–Loosen the screws at the looper eccentric 3.
–Turn and stake out the eccentric.
–Tighten the screws.
–Loosen the screws at the spreader eccentric 4.
–Turn and stake out the eccentric.
–Tighten the screws.
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2.3 Rotary Thread Take-up Disc
Caution: Danger of injury!
Switchthemainswitchoff.
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
disc to butt against the right surface 3.
Correction
–Remove the tension plate 1.
–Loosen the screws on the belt pulley 5.
–Push the needle 4 through the bore hole in the rotary thread
take-up disc 6.
–Turn the rotary thread take-up disc until the needle 4 butts against
the surface 3.
–Fix the screws on the belt pulley 5 again.
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2.4 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.
–Turn the arm shaft in such a way that the looper turret is on the
right side (right entry point).
–Put the arresting pin 4 in the drill-hole 3 of the eccentric 2.
–Check whether the arresting pin 4 abuts in the notching 1 of the
arm.
Correction
–Loosen the screws at the eccentric 2.
–Position the eccentric with the arresting pin right on top against the
arm.
–Tighten the screws at the eccentric 2.
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3. 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.
–Switch the machine on.
The machine positions automatically.
–Check whether the needle bar is in the top dead center and
whether the looper turret is in its right end position (right entry
point).
Correction
–Switch the machine on. The machine positions automatically.
–Move the needle bar in the correct position by handwheel (right
entry point).
–Switch to the technician level.
For this purpose press the keys “P” and “ç“ simultaneously.
–Enter code “2548”.
–Press key “OK”.
The control switches to the technician level.
–Select menu “603”.
–Press key “OK”.
–Loosen screw 1 at the switching segment 2.
–Turn the segment in such a way that the light barrier 3 at the flank
4 engages.
The switching signals are indicated on the control panel (inlet r0)
–Tighten the screw 1 at the switching segment 2.
Note:
The switching segment must be in the middle of the light barrier.
–Switch the machine on and check the positioning.
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4. Aligning the looper turret
Caution: Danger of injury!
Switchthemainswitchoff.
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.
–Switch the machine on.
The machine and the fabric support plate run to their initial
position.
–Switch the machine off.
–Check whether the looper turret 2 can be staked out with arresting
pin 1.
Correction
–Remove the clamping plates 4.
–Switch the machine on.
The machine runs to its initial position.
–Switch the machine off.
–Loosen the clamping screw at the toothed belt wheel with the
hexagonal spanner 3.
–Turn the looper turret in such a way that it can be staked out
with pin 1.
–Tighten the clamping screw with the hexagonal spanner 3.
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5. Aligning the needle bar parallel to the looper turret
Caution: Danger of injury!
Switchthemainswitchoff.
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.
–Remove the cutting block.
–Unscrew the finger protection and the head cover.
Note !
Do not separate the cable from the head cover.
–Switch the machine on.
The machine runs to its initial position.
–Switch the machine off.
–Stake out the looper turret with arresting pin 2.
–Position an angle 5 at the right side 6 of the looper turret.
–Check whether the screw 7 at the needle bar guide 8 abuts on the
angle.
Correction
–Loosen the screws 9 at the toothed belt wheel 10.
–Turn the needle bar guide 4 correspondingly.
–Tighten the screws 9 at the toothed belt wheel 10.
–Switch the machine on.
–Check the needle bar position.
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X2
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6. 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.
The distance between reference switch 5 and switch sheet 6 must not
exceed 0.5 mm.
–Switch the machine on.
–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 “608” with the key “+”.
–Switch the menu on with key ”OK”.
The machine runs to its initial position.
–Switch the machine off.
–Check the dimension X1 with the slide gauge 2 (right edge of the
throat plate groove to the left edge of the fabric support plate).
–Check the dimension X2 (left edge of the throat plate groove to the
right edge of the fabric support plate).
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Correction
–Switch the machine on and press the keys “P” and “ß”onthe
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.
–Switch the menu on with key ”OK”.
Caution: Danger of injury!
Exercise utmost caution when making adjustments with the machine
running.
–Shift the fabric support plate manually in such a way that the
dimensions X1 and X2 are equal.
–Loosen screw 7.
–Turn the switch sheet 6 to the switch actuation point.
When turning the switch sheet 6 the switching signals are indicated
on the control panel (inlet r1).
–Tighten screw 7.
–Switch the machine off and on again.
–Let the machine move to its initial position and check the position
of the fabric support plate.
Correction of the distance between reference switch and switch
sheet
–Loosen the nuts 8.
–Screw the reference switch 5 out or in so that the distance between
reference switch 5 and switch sheet 6 does not exceed 0.5 mm.
–Tighten the nuts 8.
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7. 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. 113 mm.
The distance between reference switch and switch sheet must not
exceed 0.5 mm.
–Switch the machine on.
–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 “608” with the key “+”.
–Switch on the menu with key ”OK”.
The machine runs to its initial position.
–Switch the machine off.
–Check the distance between the edge 3 of the fabric support plate
and the front edge 1 of the throat plate support.
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Correction
–Switch the machine on and press the keys “P” and “ß”onthe
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.
–Switch the menu on with key ”OK”.
Caution: Danger of injury!
Exercise utmost caution when making adjustments with the machine
running.
–Shift the fabric support plate manually to the desired measurement.
–Loosen the screws 5.
–Set the switch sheet 4 to the switch actuation point.
When shifting the switch sheet 4 the switching signals are
indicated on the control panel (inlet r2).
–Tighten the screws 5.
–Switch the machine off and on again.
–Let the machine move to its initial position and check the
measurement.
Correction of the distance between reference switch and switch
sheet
–Loosen the nut.
–Screw the reference switch 6 out or in so that the distance between
reference switch 6 and switch sheet 4 does not exceed 0.5 mm.
–Tighten the nut.
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