Duerkopp Adler 650-16 Operating instructions

650-16
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Service instructions

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prohibited without prior written permission of Dürkopp Adler AG.
Copyright © Dürkopp Adler AG - 2012

Table of contents
Service Instructions 650-16 Version 00.0 - Last Updated 09/2012 1
1 General...................................................................................................................... 3
1.1 Scope of this Guide.................................................................................................... 3
1.2 Declaration of conformity ........................................................................................... 3
1.3 Applicable documents................................................................................................ 3
1.4 Transport damage...................................................................................................... 3
1.5 Limited liability............................................................................................................3
2 Safety instructions................................................................................................... 4
2.1 General Safety instructions........................................................................................ 4
2.2 Marking of safety instructions..................................................................................... 5
3 Environmental protection notes............................................................................. 7
3.1 General environmental protection notes.................................................................... 7
3.2 Highlighting of environmental protection notes .......................................................... 7
4 Work principles........................................................................................................ 8
4.1 Symbols in the text..................................................................................................... 8
4.2 Order of settings......................................................................................................... 9
4.3 Cable routing.............................................................................................................. 9
4.4 Bolts in safety covers................................................................................................. 9
4.5 Removing covers ..................................................................................................... 10
4.5.1 Access to the underside of the machine.................................................................. 10
4.5.2 Removing and replacing the top cover..................................................................... 11
4.5.3 Removing and replacing the rear arm cover............................................................ 11
4.5.4 Removing and replacing the fabric base and column cover .................................... 12
4.5.5 Removing and replacing the needle plate................................................................ 13
4.6 Surfaces on shafts ................................................................................................... 14
4.7 Locking the sewing machine.................................................................................... 14
5 Adjusting the lightbeam sensor disk................................................................... 16
6 Adjusting the hook and the needle bar................................................................ 18
6.1 Adjusting the looping stroke position and hook spacing .......................................... 19
6.2 Adjusting the needle bar height................................................................................ 20
7 Adjusting the thread passage on the centre part mount ................................... 21
8 Adjusting the needle plate position ..................................................................... 22
9 Adjusting the thread trimmer................................................................................ 23
9.1 Adjusting the control curve....................................................................................... 23
9.1.1 Position of the control curve..................................................................................... 23
9.1.2 Distance between control curve and roller............................................................... 25
9.2 Replacing and adjusting thread puller blades.......................................................... 27
9.3 Replacing the counter-blade.................................................................................... 28
9.4 Adjusting the counter-blade and cutting pressure.................................................... 29
9.5 Adjusting the thread puller blade stroke................................................................... 30
10 Adjusting the central foot...................................................................................... 31
11 Adjusting the toothed belt..................................................................................... 32
11.1 Toothed belt between top and bottom shaft............................................................. 32
11.2 Toothed belt for hook drive ...................................................................................... 33
12 Replacing and adjusting the top transport belts ................................................ 35
12.1 Replacing the top transport belts ............................................................................. 35
12.2 Adjusting the top transport belts............................................................................... 37

Table of contents
Service Instructions 650-16 Version 00.0 - Last Updated 09/2012 2
13 Replacing and adjusting the bottom transport belts.......................................... 39
13.1 Replacing the bottom transport belts ....................................................................... 39
13.2 Adjusting the bottom transport belts......................................................................... 41
13.3 Replacing sprockets................................................................................................. 42
14 Checking the sewing foot lifting gear.................................................................. 43
15 Electrical thread tensioner.................................................................................... 46
15.1 Fitting and removing the electrical thread tensioner ................................................ 46
15.2 Replacing the thread tensioning spring.................................................................... 48
15.3 Adjusting the spring force......................................................................................... 50
15.4 Adjusting the spring stroke....................................................................................... 51
16 Adjusting the thread regulator.............................................................................. 52
17 Adjusting the bobbin winder................................................................................. 53
17.1 Setting the fill volume............................................................................................... 53
17.2 Setting the winding form of the bobbin winder......................................................... 54
17.3 Setting the winding tension of the bobbin winder..................................................... 54
18 Service settings via software................................................................................ 55
18.1 Basic software operation.......................................................................................... 55
18.2 Accessing technician level....................................................................................... 56
18.3 Menu items at technician level................................................................................. 58
18.3.1 Menu item default program...................................................................................... 58
18.3.2 Menu item Machine config....................................................................................... 59
18.3.3 Menu item user config.............................................................................................. 62
18.3.4 Menu item service.................................................................................................... 63
18.4 Installing software with a dongle.............................................................................. 73
18.5 Checking the key functionality at the control panel.................................................. 74
19 Maintenance work.................................................................................................. 75
19.1 Lubrication................................................................................................................ 75
19.2 Cleaning................................................................................................................... 76
20 Appendix................................................................................................................. 77
20.1 Software error messages......................................................................................... 77
20.2 Circuit diagram......................................................................................................... 81

General information
Service Instructions 650-16 Version 00.0 - Last Updated 09/2012 3
1 General information
1.1 Scope of this Guide
This guide describes settings and maintenance work on the Custom Ma-
chine 650-16 for sewing in sleeves. It applies to all subclasses. Intended
use and installation are described in the Operating instructions.
1.2 Declaration of conformity
The machine conforms with the European regulations stated in the decla-
ration of conformity or incorporation.
1.3 Applicable documents
The machine contains built-in components by other manufacturers, e.g.
drive motors. The respective manufacturers have performed risk assess-
ment for these supply parts and declared the conformity of their design
with pertinent European and national regulations. Intended use of the
built-in components is described in the individual third party manufactur-
ers' guides.
1.4 Transport damage
Dürkopp Adler is not liable for breakage and transport damage. Please
check the deliver carefully immediately on receipt. Claim against the for-
warder for damage. This also applies if the packaging is undamaged.
Leave the machine device and packaging material in the state it was in
when you ascertained the damage. This will help you assert your claim
against the forwarder.
Report all other complaints without delay after receipt of delivery to
Dürkopp Adler.
1.5 Limited liability
All details and information in this guide were compiled taking the current
state of the art and applicable standards and regulations into consider-
ation.
The manufacturer accepts no liability in case of damage due to:
• failure to observe this guide
• unintended use
• unauthorized modifications to the machine
• use of untrained staff
• breakage and transport damage
• use of non-approved spare parts

Safety instructions
Service Instructions 650-16 Version 00.0 - Last Updated 09/2012 4
2 Safety instructions
This chapter contains basic instructions for your safety. Read these in-
structions carefully before you install, program, maintain or operate the
machine.
Always follow the provisions in the safety instructions. Failure to observe
can lead to severe injury and damage to property.
2.1 General safety precautions
Unauthorized persons must not work on or with the machine. Every per-
son working on or with the machine must read the operating instructions
before doing so.
Use the machine in line with the guide only.
The operating instructions must be kept at the machine's place of use.
Observe the general safety and accident protection regulations and legal
requirements on occupational safety and environmental protection.
If you use supply parts, always observe the safety instructions and oper-
ating guides by the third party manufacturers.
All warning signs on the machine must always be kept in legible state and
must not be removed. Missing or damaged signs must be replace imme-
diately.
In the following situations, always de-energize the machine at the main
switch or by unplugging the mains plug:
• Threading
• Replacing the needle or other sewing tools
• Leaving the workplace
• Performing servicing, maintenance and repairs
Check the machine during use for signs of visible damage. Interrupt your
work if you notice any change in the machine's behavior. Report all chang-
es to your superior. Do not continue to use a damaged machine.
Machines or machine parts that have reached the end of their service life
must not be operated. Dispose of these machines in line with environmen-
tal legislation.
Only qualified and trained staff are allowed to install the machine. Any per-
son installing the machine must read the installation instructions before
doing so.
Only qualified and trained staff are allowed to perform servicing, mainte-
nance and repairs. Any person maintaining or adjusting the machine must

Safety instructions
Service Instructions 650-16 Version 00.0 - Last Updated 09/2012 5
read the service instructions before doing so.
Do not remove or disable safety equipment. If this is unavoidable for re-
pairs or servicing, immediately replace and enable the safety equipment
after completing the work.
Work on the machine's electrical equipment must be performed by a qual-
ified electrician.
The connecting cable must have a plug with country-specific approval.
Only qualified and trained staff are allowed to connect the plug to the pow-
er cable.
Work on live parts and equipment is prohibited. Exceptions are regulated
in DIN VDE 0105.
Onlyuse originalsparepartsbythemanufacturer.Incorrector faultyspare
parts can impair safety and damage the machine.
2.2 Marking of safety instructions
Colored bars highlight the safety instructions in the text.
Signal words indicate the severity of the risk:
•Danger:
Certainty of serious or fatal injury.
•Warning:
Risk of serious or fatal injury.
•Caution:
Risk of moderate or minor injury.
•Attention:
Risk of damage.
In case of dangers for persons, these symbols indicate the type of danger:
General danger
Danger due to pointed objects
Danger due to electric shock
Danger due to crushing

Safety instructions
Service Instructions 650-16 Version 00.0 - Last Updated 09/2012 6
Examples for marking of safety instructions in the text:
Type and source of danger
Consequences in case of failure to observe
Measures for preventing the danger
Danger notice where failure to observe will lead to fatal or
serious injury.
Danger
Type and source of danger
Consequences in case of failure to observe
Measures for preventing the danger
Danger notice where failure to observe can lead to fatal or
serious injury.
Warning
Type and source of danger
Consequences in case of failure to observe
Measures for preventing the danger
Danger notice where failure to observe can lead to moder-
ate or minor injury.
Caution
Type and source of danger
Consequences in case of failure to observe
Measures for preventing the danger
Danger notice where failure to observe can lead to damage to proper-
ty.
Attention

Environmental protection notes
Service Instructions 650-16 Version 00.0 - Last Updated 09/2012 7
3 Environmental protection notes
3.1 General environmental protection notes
Dispose of machines or machine parts that have reached the end of their
service life responsibly, observing the legal requirements on environmen-
tal protection.
Use consumables conservatively and dispose of them responsibly, ob-
serving the legal requirements on environmental protection.
3.2 Highlighting of environmental protection notes
Green bars mark environmental protection notes in the text.
The following symbols state the type of environmental measure:
Example for marking of environmental protection notes in the text
Note on responsible disposal
Type and source of danger
Consequences in case of failure to observe
Measures for preventing the danger
Danger notice where failure to observe can lead to damage to
property.
Environmental

Work principles
Service Instructions 650-16 Version 00.0 - Last Updated 09/2012 8
4 Work principles
4.1 Symbols in the text
The following symbols at the margins and in the text show what type of in-
formation the text includes.
Correct setting
Indicates the correct setting.
Malfunctions
Indicates malfunctions that can occur in case of incorrect settings.
Cover
States which covers you need to remove to access the components to be
adjusted.
Steps for servicing, maintenance and installation
Steps via the software control panel
The individual steps are numbered:
1. First individual step
2. Second individual step
3. Third individual step, etc.
You must observe the order of the individual steps.
Results of an action
If a change to the machine is made in an individual step, or a new mes-
sage appears in the display, which is important for you as feedback, this
change is indicated by an arrow: 
Important
Shows you what to pay attention to in the current step.
Information
Provides additional information.
Order
States which work you must perform before or after the setting.
References
 This is followed by a reference to another part of the text.
1.
2.
3.
...


Work principles
Service Instructions 650-16 Version 00.0 - Last Updated 09/2012 9
4.2 Order of settings
Observe order Always observe the stated order for the individual setting steps.
Always observe all notes marked with a in the margin on preconditions
and follow-up settings.
4.3 Cable routing
Bundle cables Make sure that all cables are routed in the machine that they do not inter-
fere with the function of moving parts.
1. Lay over length cables in tidy loops.
2. Tie up loops with cable ties.
Attach loops to stationary parts where possible. The cables must be
fixed in place.
3. Cut off protruding cable ties.
4.4 Bolts in safety covers
There is no need to fully remove bolts in safety cover from their holes. As
soon as the bolts have been loosened sufficiently for you to remove the
cover, you can remove the cover. The bolts either stay in the housing or
inthecover.Inthetext,theseboltsaremarkedwiththesupplement(safety
cover).
Damage to machine possible due to incorrect order.
Always keep to the work order stated in this guide.
Attention
Machine damage and functional impairment possible due to incor-
rect cable routing.
Excess cable can impair the function of moving machine parts. This im-
pairs the sewing function and can cause damage.
Route excess cable as described above.
Attention

Work principles
Service Instructions 650-16 Version 00.0 - Last Updated 09/2012 10
4.5 Removing covers
For many adjustments you first need to remove the machine covers to ac-
cess the components.
This describes how to remove and replace the covers. The text for the in-
dividual settings then simply states which cover you need to remove.
4.5.1 Access to the underside of the machine
To access the components on the underside of the machine, you must tilt
the upper part of the machine back.
Figure 1: Tilting the machine upper part back and returning to upright position
Tilting the machine upper part back
1. Tilt the upper part of the machine (1) back to the stop
2. Release all 5 bolts (3) (Safety cover p. 9).
3. Remove the tray (2) in downward direction.
Returning the machine upper part to upright position
1. Replace the tray (2).
2. Tighten all 5 bolts (3) (Safety cover p. 9).
3. Prop up the machine upper part (1).
Risk of injury
Crushing hazard due to moving parts
Switch off the sewing machine before you remove or re-
place covers.
Warning
1
2
3
33
3
3
(1) - Upper part of machine
(2) - Tray (3) - Bolts

Work principles
Service Instructions 650-16 Version 00.0 - Last Updated 09/2012 11
4.5.2 Removing and replacing the top cover
Figure 2: Removing and replacing the top cover
Removing the top cover
1. Loosen both top cover bolts (1)
2. Remove the top cover (2)
Replacing the top cover
1. Replace the top cover (2)
2. Tighten both top cover bolts (1)
4.5.3 Removing and replacing the rear arm cover
Figure 3: Removing and replacing the rear arm cover
Removing the rear arm cover
1. Release all 5 bolts (1) (Safety cover p. 9) on the rear arm cover.
2. Remove the rear arm cover (2).
Replacing the rear arm cover
1. Replace the rear arm cover (2).
2. Tighten all 5 bolts (1) (Safety cover p. 9) on the rear arm cover.
1
2
(1) - Top cover bolts (2) - Top cover
1
2
(1) - Bolts (2) - Rear arm cover

Work principles
Service Instructions 650-16 Version 00.0 - Last Updated 09/2012 12
4.5.4 Removing and replacing the fabric base and column cover
Figure 4: Removing and replacing the fabric base and column cover
Removing the fabric base and column cover
1. Release both bolts (1) (Safety cover p. 9).
2. Slightly raise the fabric base (3) and pull off to the left.
3. Slightly raise the column cover (2) and pull off to the left.
Replacing the fabric base and column cover
1. Replace the column cover (2) from the top left.
2. Replace the fabric base (3) from the top left.
3. Tighten both bolts (1) (Safety cover p. 9).
3
2
1
3
(1) - Bolts
(2) - Column cover
(3) - Fabric base

Work principles
Service Instructions 650-16 Version 00.0 - Last Updated 09/2012 13
4.5.5 Removing and replacing the needle plate
Figure 5: Removing and replacing the needle plate
Removing the needle plate
1. Remove the fabric base and column cover. (Chap. 4.5.4, p. 12)
2. Loosen the bolts (4)
3. Remove the guide piece (3)
4. Take off the needle plate (5) in upward direction.
Replacing the needle plate
1. Replace the needle plate (5) from the top.
2. Inserttheguidepiece(3)sothatthepins(1)lockintotheneedleplate (5)
and the central part holder (2) fits into the recess (6) on the hook (7).
3. Secure the guide piece (3) with bolts (4).
4. Replacing the fabric base and column cover.(Chap. 4.5.4, p. 12)
456
7
1
23
(1) - Pins
(2) - Centre part holder
(3) - Guide piece
(4) - Bolts
(5) - Needle plate
(6) - Recess
(7) - Hook

Work principles
Service Instructions 650-16 Version 00.0 - Last Updated 09/2012 14
4.6 Surfaces on shafts
Bolt onto the sur-
face
Figure 6: Surfaces on shafts
Some shafts have flat surfaces at the parts where the components are
bolted on. This makes the connection more stable and adjustment easier.
Always take care that the bolts are fully seated on the surface.
4.7 Blocking the sewing machine
For some adjustments, the machine must be blocked. To do so, insert the
blocking pin from the accessory kit into a groove on the arm shaft crank to
block the arm shaft.
Figure 7: Locking pin and insert groove on the arm shaft crank
The handwheel (3) is marked with numbers for orientation. If you turn the
handwheel to a position where one of the number is next to the mark (4),
the corresponding groove on the arm shaft crank (2) is located below the
opening for the locking pin (1).
2
1
(1) - Surface (2) - Shaft
1
3
4
2
(1) - Locking pin
(2) - Arm shaft crank with insert groove (3) - Handwheel (4) - Mark

Work principles
Service Instructions 650-16 Version 00.0 - Last Updated 09/2012 15
There are 3 locking positions for the following settings:
•Position 1
• Loop stroke position
• Hook clearance to needle
•Position 4
• Control curve for thread cutter
•Position 6
• Reference position for control unit with needle at top dead centre
Positions 2, 3 and 5 are not used.
Figure 8: Blocking the sewing machine
Blocking the machine
1. Pull the plug (1) out of the locking opening (2)
2. Turn the handwheel until the number for the desired locking position is
next to the mark (4).
3. Push the locking pin (3) through the locking opening (2) intothe groove
on the arm shaft crank.
The numbers on the handwheel provide rough orientation. To hit the
groove precisely, you might need to turn the handwheel slightly.
Releasing the lock
1. Remove the locking pin (3)
2. Insert the plug (1) into the locking opening (2)
4
1
2
3
(1) - Plug
(2) - Locking opening (3) - Locking pin (4) - Mark

Adjusting the lightbeam sensor disk
Service Instructions 650-16 Version 00.0 - Last Updated 09/2012 16
5 Adjusting the lightbeam sensor disk
The lightbeam sensor disk is used as a reference for positioning by the
control unit.
It must be adjusted so that the incoming edge ofthe 180° disk lines up pre-
cisely at the height of the lightbeam slot - in rotational direction of the ma-
chine - when the needle is at bottom dead centre.
Check the correct setting
Lock the machine in Position 6 (p. 15).
The 180° disk points to the front and it lower edge is precisely lined up
with the lightbeam slot.
Malfunctions in case of incorrect settings.
• Damage to fabric, wrinkling
• Incorrect needle position, needle jams in hole
• Incorrect transport times
• Incorrect thread trimming
• Poor sewing results
Cover
• Access to the underside of the machine (Chap. 4.5.1, p. 10)
Risk of injury
Crushing hazard due to moving parts
Switch off the sewing machine before you adjust the light-
beam sensor disk
Warning

Adjusting the lightbeam sensor disk
Service Instructions 650-16 Version 00.0 - Last Updated 09/2012 17
Figure 9: Adjusting the lightbeam sensor disk
Adjusting steps
1. Lock the machine in Position 6 (p. 15).
2. Remove both grub screws (1) on the sensor disk.
3. Turn the sensor disk so that the 180° disk (3) points to the front and its
lower edge is precisely lined up with the lightbeam slot (2).
Important: The sensor disk must be aligned laterally so that the 180°
disk (3) does not touch the lightbeam housing.
4. Tightenbothgrubscrews(1)withoutchangingthepositionofthesensor
disk.
5. Release the lock (p. 15).
3
1
2
(1) - Grub screws (2) - Lightbeam slots
(3) - 180° disk

Adjusting the hook and the needle bar
Service Instructions 650-16 Version 00.0 - Last Updated 09/2012 18
6 Adjusting the hook and the needle bar
The following 3 settings must be adjusted to match one another:
• Loop stroke position
• Hook clearance to needle
• Height of needle bar
Loop stroke position and loop stroke
The loop stroke position is the position of the hook at which the hook tip
points precisely at the centre line of the needle.
The looper stroke is the length of the stroke from bottom dead centre of
the needle bar to the height at which the hook is in looper stroke position.
The looper stroke on the 650-16 is 1.8 mm.
Figure 10: Loop stroke position
Check the correct setting
When the machine is locked in looper stroke position (locking position 1)
(p. 15), the hook tip must point directly at the centre line of the needle.
The needle must be aligned so that the surface of the hollow groove is par-
allel to the running direction of the hook tip. In terms of height, the hook tip
must be in the lower third of the hollow groove.
Malfunctions in case of incorrect settings.
• Damage to the hook
• Damage to the needle
• Incorrect sewing
• Thread break
Order
Preconditions:
• Make sure a straight and undamaged needle is fitted (Operating
instructions Chap. 8.7 Replacing the needle)
13
2
(1) - Centre line of needle (2) - Hook tip
(3) - Hollow groove