Duerkopp Adler 609 Operating instructions

609
Spezialnähmaschine
Serviceanleitung
Service Instructions
Postfach 17 03 51, D-33703 Bielefeld • Potsdamer Straße 190, D-33719 Bielefeld
Telefon +49 (0) 521 / 9 25-00 • Telefax +49 (0) 521 / 9 25 24 35 • www.duerkopp-adler.com
Ausgabe / Edition: Änderungsindex Teile-Nr./Part.-No.:
01/2008 Rev. index: 00.0 Printed in Federal Republic of Germany 0791 609641
D
GB

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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 - 2008

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 for the class 609
(Edition 01/2008)
1. General
1.1 Gauge Set ................................................... 4
2. Position of needle and needle hole ................................... 5
3. Material presser foot
3.1 Heightofthematerialpresserfoot .................................... 6
3.2 Timingofthemovementofthematerialpresserfoot.......................... 7
3.3 Strokeofthematerialpresserfoot .................................... 8
4. Opening the thread tension
4.1 Mechanical opening of the thread tension ................................ 9
4.2 Electromagnetic opening of the thread tension ............................. 10
4.3 ThreadControllerSpring.......................................... 11
5. Pre-adjustment to the needle bar height ............................... 12
6. Hook settings
6.1 Loop stroke and clearance of the hook point to the needle ...................... 13
7. Thread trimmer
7.1 Function sequence .............................................. 14
7.2 Threadtrimmerdrive............................................. 15
7.3 Knife carrier and thread-pulling knife ................................... 16
7.4 Hookshaftandknifecarrier ........................................ 17
7.5 Timingofthetrimmingprocess(controlcam).............................. 18
7.6 Position of the counter knife ........................................ 19
7.7 Cutting pressure of the counter knife ................................... 20
7.8 Re-sharpening the counter knife...................................... 21
7.9 Position of the thread guiding sheet.................................... 22
8. Bobbin winder
8.1 Function of the bobbin winder ....................................... 23
8.2 Bobbin fill quantity .............................................. 24
9. Oil lubrication
9.1 General..................................................... 25
9.2 Lubrication points............................................... 26
10. Maintenance ................................................. 27
11. Summary of all sewing machine settings ............................... 28
GB

GB
1. General
These service instructions describe the adjustments that can be made
to the 609-class special sewing machine.
609-100101: The single-needle lockstitch cylinder arm
machine with electromagnetic thread trimmer.
ATTENTION!
The operations described in these service instructions may only be
carried out by qualified staff or other appropriately trained persons!
Caution Risk of Injury!
Always switch off main switch before any repair, alteration and
maintenance.
Any adjustment work and function testing conducted while the machine
is running should follow all safety measures with the greatest possible
caution.
These service instructions describe the adjustment of the sewing
machine in a logical order.
Please observe that various setting positions are dependent on each
other. Thus it is essential that the settings be made in the order
described.
For all adjustments of parts involved in the stitch formation, a new
undamaged needle must be inserted.
ATTENTION!
All colored parts were set at the factory and should only be loosened
by skilled personnel.
3

1.1 Gauge set
You can use the setting gauges included in the gauge set to precisely
check and adjust the sewing machine.
Pos. Setting gauge Order no. Use
1 Gauge 0981 150003 Loop stroke
2 Block 0981 150002 Loop stroke
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2. Position of needle and needle hole
Caution Risk of Injury!
Turnthemainswitchoff.
Check and set the position of the needle and needle hole only when
the sewing machine is turned off.
Rule and control
The needle-bar link must be standing over the needle hole, so that the
needle penetrates the middle of the hole.
Adjustment
–Take off the material presser foot.
–Turn the handwheel until the needle is positioned directly over the
needle hole.
–Loosen screw 2.
–Align the needle-bar link.
–Tighten screw 2 again.
–Mount and align material presser foot 1.
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3. Material presser foot
3.1 Height of the material presser foot
Caution Risk of Injury!
Turnthemainswitchoff.
Check and set the height of the material presser foot only with the
sewing machine turned off.
Rule and control
The distance between the material presser foot 2 and the needle plate
1 should be 0.3 mm.
The setting can be made with a feeler gauge.
–Turn handwheel until the material presser foot is at its lowest point.
–Use the feeler gauge to check is the height is correct.
The spool must abut the radius of the retainer (the left side).
During the entire course of the needle movement, the guide piece 5
should neither strike the top, nor protrude out from the guide 6.
Adjustment
Setting the height of the material presser bar
–Loosen clamping screws 3.
–Set the material presser foot higher or lower (place the feeler
gauge under the foot).
–Press the retainer against the spool.
–Tighten screws 3 again.
Setting the guide piece
–Loosen screw 4.
–Push the guide piece 5 accordingly.
–Tighten screw 4 again.
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3.2 Timing of the movement of the material presser foot
Caution Risk of Injury!
Turnthemainswitchoff.
Check and set the movement of the material presser foot only with the
sewing machine turned off.
Rule and control
During the needle-insertion cycle, the material presser foot 1 must be
at its lowest point when the descending needle penetrates the needle
plate.
–Turn handwheel until the material presser foot is at its lowest point.
–Observe the movement of the needle.
Adjustment
–Loosen the set screw 2.
–Adjust the cam 3.
–Tighten set screw 2 again.
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3.3 Stroke of the material presser foot
Caution Risk of Injury!
Turnthemainswitchoff.
Check and set the stroke of the material presser foot only with the
sewing machine turned off.
Rule and control
When the stroke is set at its highest (lever 1 is at upper stop position),
there should be 20 mm clearance between the highest position of the
material presser foot and the needle plate.
–Turn handwheel until the material presser foot is at its highest
point.
–Measure the clearance.
Adjustment
–Loosen screw 3 with needle bar at the bottom dead center.
–Adjust the crank 2.
–Tighten screw 3 again.
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4. Opening the thread tension
Functions
1. The needle thread tension is opened mechanically,
·on every stitch, when the thread lever is located 2 mm past the
upper dead center.
2. The needle thread tension is opened electromagnetically,
·during the thread trimming.
4.1 Mechanical opening of the thread tension
Caution Risk of Injury!
Turnthemainswitchoff.
Check and set the opening of the thread tension only with the sewing
machine turned off.
Prerequisite:
The positioning of the control unit is setup as follows: in sewing mode
after every stitch, the thread lever is located 2 mm past the upper dead
center.
The position is determined by the preset value of the parameters.
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Rule and control
When the thread lever is exactly at its UDC, the tension discs should
be closed.
As soon as the thread lever is about 2 mm behind the upper dead
center (UDC) point, the needle thread tension should be open to allow
a pulling of the thread.
This setting will guarantee a sufficient stitch formation despite regular
opening of the tension discs.
In the maximally open position, there should be 1.0 mm distance
between the tension discs 2.
–Turn the handwheel until the thread lever is in position. Then keep
turning slowly and observe the needle thread tension.
–Check the distance between the tension discs.
Adjustment of the distance
–Loosen the set screw 1, while in the maximally-open position.
–Move the thread tension bolts accordingly.
–Tighten set screw 1 again.
Adjustment of the timing
–Loosen screw 4 at the cam 3.
–Turn the cam.
–Tighten screw 4 again.
10
UDC
2mm

Notes:
11
GB

4.2 Electromagnetic opening of the thread tension
Caution Risk of Injury!
Turnthemainswitchoff.
Check and set the opening of the thread tension only with the sewing
machine turned off.
Rule and control
In its unopened state, the lugs 5 of the trigger plate should be
positioned so that they do not press the tension discs 4 apart from
each other.
The magnet must be positioned so that the trigger plate does not jump
out of the guide 2.
–Visual control for unopened state
In the opened state, the needle thread must pass unimpeded through
the tension discs 4.
Adjustments for the unopened state
–Loosen locknut 7.
–Turn bolts 6 in or out, according to adjustment.
–Tighten locknut 7.
Adjustments for the opened state
–Loosen screws 3 at the mounting sheet.
–Move the magnets 1 according to adjustment.
–Tighten screws 3 at the mounting sheet.
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5
4

4.3 Thread controller spring
Caution Risk of Injury!
Turnthemainswitchoff.
Set the thread controller spring only with the sewing machine turned
off.
Rule and control
The thread controller spring 4 must hold the needle thread under minor
tension from the highest position of the thread lever to the moment the
needle’s eye penetrates the fabric.
The spring tension should be lower than the needle thread tension.
The thread controller spring 4 may only touch on the stop 3 when the
needle has entered the sewing material up to the eye.
Adjustment of the spring travel
–Loosen screw 1.
–Turn stop sleeve 3.
–Tighten screw 1 again.
Adjustment of the spring tension
–Loosen screw 1.
–Adjust spring washer 2, without changing the position of the stop
sleeve 3.
Turning the washer clockwise equates to less spring tension.
Turning the washer counter-clockwise equates to more spring
tension.
–Tighten screw 1, without changing the position of stop sleeve 3 or
spring washer 2.
Note
The settings for the spring path and spring tension apply only for
normal thread thicknesses. With extremely thick or thin needle threads
or sewing materials other settings may be required.
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5. Pre-adjustment to the needle bar height
Caution Risk of Injury!
Turnthemainswitchoff.
Set the needle bar height only with the sewing machine turned off.
Rule and control
There must be 16 mm between the lower edge of the needle bar and
the needle plate, when the needle bar 1 is located at its bottom dead
center.
–Turn the handwheel until the needle bar is located in the bottom
dead center.
–Check the distance.
Adjustment
–Loosen screws 2.
–Move the needle bar 1.
–Re-tighten screws 2. Make sure that the thread guide is at an angle
of 45° to the machine axis (see diagram). approx. 45°
ca. 45°
14
2
1
1
16 mm

6. Hook settings
6.1 Loop stroke and clearance of the hook point to the needle
Caution Risk of Injury!
Turnthemainswitchoff.
Check and set the loop stroke only with the sewing machine turned off.
Rule and control
The loop stroke (2 mm) is the run of the needle bar from the bottom
dead center up to the point where the hook point 1 lies at the middle of
the needle.
–Insert a needle with size of Nm 80 (E1) or Nm 100 (E2).
–Using the handwheel, turn the machine so that the needle bar is
located at its bottom dead center.
–Fix the loop stroke gauge and the block (see chapter 1.1 Gauge set)
according to the opposite picture. Tighten the screw of the block.
–Pull out the loop stroke gauge and turn the handwheel until the block
hits the needle bar rocker. The needle is now in loop stroke position.
–In this position the hook point 1 must lie at the middle of the needle.
In the loop stroke position, the hook point should be located in the
lower half or lower third of the needle furrow.
Adjustment
–Loosen screws 2 at the hook.
–Turn the hook on the hook shaft.
–The hook point 1 must lie at the middle of the needle.
–Thereby the clearance between hook point 1 and the furrow of the
needle must be 0.1 mm.
–Tighten screws 2 again.
–Re-adjust the needle bar height if necessary (see Chapter 5).
ATTENTION!
When a needle with a different size is inserted:
–Check the clearance of the hook to the needle and adjust if
necessary.
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7. Thread trimmer
7.1 Function sequence
The thread trimmer is switched on electromagnetically.
–To trigger the trimming sequence, step back completely on the
pedal during sewing.
·The sewing machine runs at trimming speed (150 min-1).
·When the 1st position is reached, the solenoid for the thread
trimmer is switched on.
·The cutout arm presses the crank 1 against the control cam 2.
·The thread-pulling knife 4 is thereby swung completely away from
the counter knife 3.
·Thus, the thread-pulling knife catches first the hook thread and
then the needle thread.
·The control cam 2 swings the thread-pulling knife 10.16 cm the
direction of the counter knife 3.
·The needle thread tension opens.
·The thread-pulling knife pulls needle thread from the spool and
bobbin thread from the bobbin.
·The threads are cut shortly before the high position of the thread
lever.
·The sewing drive stops after turning backward.
·The solenoids for the thread tension opening and the thread
trimmer are switched off.
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