DURKOPP ADLER 580 - User manual

Manual, complete
580
Double-chainstitch buttonhole automat
Single-chainstitch automat for stitched eyelets
Operating Instructions
Installation Instructions
Service Instructions
Postfach 17 03 51, D-33703 Bielefeld  Potsdamer Straße 190, D-33719 Bielefeld
Telefon + 49 (0 5 21 / 9 25-00  Telefax + 49 (0 5 21 / 9 25 24 35  www.duerkopp-adler.com

!
Ausgabe / Edition: 10/2005 Printed in Federal Republic of Germany Teile-Nr./Part.-No.: 0791 580001

580
Manual, complete
Contents
Operating Instructions
Installation Instructions
Service Instructions
Interconnection-diagram
9890 580001 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 - 2005.

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 580
1. General notes
1.1 Necessaryprogramsetting......................................... 5
2. Adjusting the locking positions
2.1 General notes ................................................. 6
2.2 Looper and spreader eccentric....................................... 7
2.3 Threadtake-updisc............................................. 8
2.4 Throweccentric................................................ 9
3. Needle bar positioning........................................... 10
4. Aligning the looper turret ......................................... 12
5. Aligning the needle bar parallel to the looper turret ........................ 15
6. Transversal motion of the fabric support plate ........................... 17
7. Longitudinal motion of the fabric support plate........................... 19
8. Clamping plates
8.1 Insertedclampingplates .......................................... 21
8.2 Aligningtheclampingplates........................................ 22
8.3 Adjusting the spreading ........................................... 23
8.4 Heightofthefabricclamps......................................... 25
8.5 Adjustingthelockingplate......................................... 26
8.6 Lockingoftheclampingplates....................................... 27
8.7 Adjustingthefabricclampingpressure.................................. 28
9. Adjusting the seam width
9.1 Presettingtheseamwidth ......................................... 29
9.2 Needle zero position ............................................. 32
10. Cutting knife (eyelet knife)
10.1 Positionofthecuttingknife......................................... 33
10.2 Settingdimensions.............................................. 35
10.3 Adjustingtheknifeparalleltothecuttingblock............................. 36
10.4 Adjustingtheknifeparalleltothecuttingblockwith“Multiflex”machines............. 37
10.5 Cuttingblockadjustment.......................................... 38
10.5.1Adjustingthecuttingblockposition(Multiflexsystem)......................... 39
10.6 Settingtheswitchforthe“Multiflex”cuttingsystem .......................... 43
10.7 Cuttingpressure ............................................... 44
10.8 Cuttingduration................................................ 44
3

Index Page:
11. Looper height ................................................ 45
12. Adjusting the loop stroke ......................................... 46
13. Needle bar height .............................................. 48
14. Distance between looper and needle.................................. 49
15. Needle protection .............................................. 50
16. Spreader.................................................... 51
17. Spreader plate ................................................ 52
18. Throat plate.................................................. 53
19. Adjusting the needle thread knife.................................... 54
20. Adjusting the fabric clamps ....................................... 56
21. Thread take-up spring ........................................... 58
22. Short trimmer for lower thread (580-112000, 580-312000)
22.1 Function sequence .............................................. 59
22.2 Initialposition................................................. 61
22.3 Adjustingthecuttingpressure/clampingpressure .......................... 63
22.4 Knife change ................................................. 64
23. Long trimmer for looper thread and gimp (580-121000 und -321000)
23.1 Cuttingpressureandcuttingmotion ................................... 65
23.2 Adjustingtheknifeoverlap......................................... 66
23.3 Position of the looper thread and gimp clamp .............................. 69
23.4 Threaddeflector ............................................... 70
24. Short trimmer for looper thread and gimp (580-141000)
24.1 Optional equipment for subclass 580-141000 .............................. 74
25. Gimp pulling device for subclass 580-141000 ............................ 75
26. Thread catcher
26.1 General notes ................................................. 76
26.2 Adjustment................................................... 77
26.3 Subsequent fitting of the thread catcher ................................. 79
27. Maintenance ................................................. 80
28. Annex
28.1 Adjusting operations without head cover ................................. 81

Index Page:
28.2 Fusesinthecontrolbox........................................... 82
28.3 Exchange of the control ........................................... 82
28.4 Adjusting the contrast of the control panel ................................ 82
29. Service menu (technician level)
29.1 Activatingtheservicemenu ........................................ 83
29.2 Quittingtheservicemenu.......................................... 83
29.3 Menustructure................................................ 84
29.3.1Menustructurewithnumbers........................................ 86
24.4 Menu items configuration automatic buttonholer ............................ 88
29.4.1 Loading position ............................................... 88
29.4.2Menuitemthrowwidth............................................ 88
29.4.3Menuitemthreadmonitor.......................................... 89
29.4.4Menuitemdutycycleofcuttingblock................................... 89
29.4.5 Menu item sewing equipment ....................................... 90
29.4.6 Menu item threading mode ......................................... 91
29.4.7 Menu item operation mode ......................................... 91
29.4.8Menuitemtensiondata........................................... 92
29.4.9MenuitemMultiflex.............................................. 93
29.5 Menu items operating configuration .................................... 94
29.5.1 Menu item language ............................................. 94
29.5.2Menuitempush-buttons........................................... 94
29.5.3Menuitembrightnessofthesewinglamp................................ 95
29.5.4 Menu item key tones ............................................. 95
29.6 Menuitemstestfunctionsmultitest.................................... 96
29.6.1Menuitemoutputtest............................................ 97
29.6.2 Menu item manual input test ........................................ 98
29.6.3 Menu item automatic input test....................................... 99
29.6.4Menuitemsewingmotortest........................................ 100
29.6.5Menuitemstepmotortest ......................................... 101
29.6.6Menuitemflashtest............................................. 102
29.6.7MenuitemRAM-test............................................. 102
29.7 Menu items test functions / Test program sewing sequence ..................... 103
29.7.1Menuitemstop................................................ 103
29.7.2Menuitemreferencestart.......................................... 103
29.7.3 Menu item continuous operation ...................................... 104
29.8 Menuitemevents............................................... 105
29.8.1Menuitemallevents............................................. 105
29.8.2Menuitemlatestevents........................................... 105
30. Error messages ............................................... 106
31. Troubleshooting............................................... 112
3

1. General notes
The service manual on hand describes the adjustment of the automatic
buttonholer 580 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!
Attention: 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:
–Turnthemainswitchoff.
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 operations 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!
3
5

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 locking position, the rotary thread take-up
disc and the eccentrics for the spreaders, the loopers and the
connecting stitch have to be in locking position, too.
The positions have been set by the manufacturer in such a way that
standard material can be sewn with the 580.
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 pins are included in the accessories of the machine and
have a diameter of 5 mm.
6
3

2.2 Looper and spreader eccentric
Caution: Danger of injury!
Turnthemainswitchoff.
Adjust the eccentrics only with the sewing machine switched off.
Standard checking
When the arm shaft is locked with locking pin 1, it should
be possible to lock the looper eccentric 3 and the spreader
eccentric 4, too.
–Lock the arm shaft with locking pin 1.
Important !
In this position the needle bar must be in the upper dead center in
front of the left stitch.
–Check with locking pin 2 whether the looper eccentric 5 and the
spreader eccentric 6 can be staked out.
Correction
–Lock the arm shaft with locking pin 1.
–Loosen the screws at the looper eccentric 3.
–Turn and lock the eccentric.
–Tighten the screws.
–Loosen the screws at the spreader eccentric 4.
–Turn and lock the eccentric.
–Tighten the screws.
3
7
64 3 25
1

2.3 Thread take-up disc
Caution: Danger of injury!
Turnthemainswitchoff.
Adjust the thread take-up disc only with the machine
switched off.
Standard checking
When the arm shaft has been locked with the locking pin 2
in such a way that the looper turret is in its left end position (left stitch),
the rotary thread take-up disc 6 should be positioned so that
a drill 4 (2 mm diameter) pushed through the drill-hole of the thread
take-up disc rests on the right surface 3.
Correction
–Unscrew the tension plate 1.
–Loosen the screws at the (timing) gear 5.
–Insert the drill 4 through the drill-hole in the thread take-up disc 6.
–Turn the thread take-up disc until the drill 4 abuts on the surface 3.
–Tighten the screws at the (timing) gear 5.
8
21
654 3

2.4 Throw eccentric
Caution: Danger of injury!
Turnthemainswitchoff.
Adjust the throw eccentric only with the machine switched off.
Standard checking
When the looper support 5 is in its right end position (right stitch),
the locking pin 4 inserted in the eccentric 2 should abut in the
indentation 1 at the arm.
–Turn the arm shaft in such a way that the looper support is on the
right side (right stitch).
–Put the locking pin 4 in the drill-hole 3 of the eccentric 2.
–Check whether the locking pin 4 abuts in the indentation 1 of the
arm.
Correction
–Loosen the screws at the eccentric 2.
–Position the eccentric with the locking pin right on top against the
arm.
–Tighten the screws at the eccentric 2.
3
9
43 2 1 5

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 centre. The looper turret is in its
right end position (right stitch) then.
–Switch the machine on.
The machine positions automatically.
–Check whether the needle bar is in the top dead centre and
whether the looper turret is in its right end position (right stitch).
10
32 1 42

Correction
–Switch the machine switch on.
The machine positions automatically.
–Move the needle bar in the correct position by handwheel (right
stitch).
–Press key “F”.
–Enter code “2548”.
–Press key “OK”.
The controls switches to the technician level.
–Select menu “Test functions".
–Press key “OK”.
–Select menu “Multitest”.
–Press key “OK”.
–Select menu “Input test”.
–Press key “OK”.
–Loosen screw 1 at the switch 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
(input S100).
–Tighten screw 1 at the switching segment 2
Note
The switching segment must be in the middle of the light barrier.
–Switch the machine off/on and check the positioning.
11
3

4. Aligning the looper turret
Caution: Danger of injury!
Turnthemainswitchoff.
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 lock the looper turret 2 with the
locking 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 locked with locking pin 1.
12
21 3

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 in the (timing) gear with
the Allen key 3.
–Turn the looper turret in such a way that it can be locked with pin 1.
–Tighten the clamping screw with the Allen key 3.
13
3
4

14
5
6
9
10
8
5
7

5. Aligning the needle bar parallel to the looper turret
Caution: Danger of injury!
Turnthemainswitchoff.
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.
–Lock the looper turret with locking pin 2.
–Position a square 5 at the right side 6 of the looper turret.
–Check whether the screw 7 at the needle bar guide 8 abuts on the
square.
Correction
–Loosen the screws 9 at the (timing) gear 10.
–Turn the needle bar guide 4 correspondingly.
–Tighten the screws 9 at the (timing) gear 10.
–Switch the machine on.
–Check the needle bar position.
3
15
1
2
4
3

16
X1
X2
432
11