DURKOPP ADLER 906 User manual

906
Service manual

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Property of Dürkopp Adler AG and protected by copyright. Any reuse of these contents,
including extracts, is prohibited without the prior written approval of Dürkopp Adler AG.
Copyright © Dürkopp Adler AG – 2014
IMPORTANT
READ CAREFULLY BEFORE USE
KEEP TO CONSULT LATER

Table of Contents
Service manual 906 - 00.0 - 11/2014 1
1 About these Service Instructions.............................................. 5
1.1 Scope of the service instructions.................................................. 5
1.2 For whom is this service instructions intended? ........................... 5
1.3 Representation conventions – symbols and characters ............... 5
1.4 Other documents .......................................................................... 6
1.5 Liability.......................................................................................... 7
1.5.1 Transport ...................................................................................... 7
1.5.2 Proper use .................................................................................... 7
2 Safety........................................................................................... 9
2.1 Basic safety instructions ............................................................... 9
2.2 Signal words and symbols used in warnings.............................. 10
3 Individual settings .................................................................... 13
3.1 Working basis ............................................................................. 13
3.1.1 Sequence of the settings ............................................................ 13
3.1.2 Cable routing .............................................................................. 13
3.1.3 Raising the machine upper section ............................................ 14
3.1.4 Lowering the machine upper section.......................................... 15
3.1.5 Removing and fitting the arm cover............................................ 16
3.1.6 Removing and fitting the head cover .......................................... 16
3.1.7 Removing and fitting the rear cover............................................ 17
3.1.8 Opening and closing the bobbin flap .......................................... 17
3.1.9 Flats on shafts ............................................................................ 18
3.1.10 Locking the machine in place ..................................................... 18
3.1.11 Putting the machine into position................................................ 19
3.2 Positioning the arm shaft crank .................................................. 20
3.3 Positioning the toothed belt pulleys ............................................ 21
3.3.1 Upper toothed belt pulley............................................................ 21
3.3.2 Lower toothed belt pulley............................................................ 22
3.4 Aligning the needle bar linkage .................................................. 23
3.5 Position of the hook and needle ................................................. 24
3.5.1 Setting the loop stroke position .................................................. 24
3.5.2 Setting the needle bar height...................................................... 26
3.5.3 Setting the hook side clearance ................................................. 27
3.5.4 Adjusting the needle guard......................................................... 29
3.5.5 Setting the needle guide............................................................. 30
3.6 Setting the bobbin housing lifter ................................................. 32
3.6.1 Setting the lifting gap .................................................................. 33
3.6.2 Setting the timing for opening..................................................... 34
3.7 Sewing foot lifter ......................................................................... 35
3.7.1 Setting the stroke position drive ................................................. 35
3.7.2 Setting the light barrier ............................................................... 36
3.7.3 Set the left stop screw ................................................................ 37
3.7.4 Setting the foot stroke to the needle stroke ................................ 39
3.7.5 Setting the presser foot height.................................................... 40
3.7.6 Setting the reference light barrier sewing axis............................ 42
3.8 Setting the needle thread tension............................................... 44
3.8.1 Setting the thread regulator ........................................................ 44
3.8.2 Setting the thread tensioning spring ........................................... 45
3.8.3 Setting the thread tension plate.................................................. 46
3.8.4 Calibrating the thread tension plate............................................ 47

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2Service manual 906 - 00.0 - 11/2014
3.9 Short thread cutter (STC) ........................................................... 48
3.9.1 General information .................................................................... 48
3.9.2 Setting the hook thread tensioner............................................... 50
3.9.3 Setting the thread-pulling knife ................................................... 51
3.9.4 Setting the counter-blade ........................................................... 53
3.9.5 Setting the cutoff position ........................................................... 55
3.10 Changing the material presser foot bar ...................................... 56
3.11 Checking the machine zero point ............................................... 58
3.11.1 Check machine zero point with gages........................................ 58
3.11.2 Check machine zero point using a semi-finished parts set......... 60
3.12 Checking the material feeder alignment ..................................... 61
3.12.1 Check alignment using gage ...................................................... 61
3.12.2 Check alignment using a semi-finished parts set. ...................... 62
3.13 Changing the drive ..................................................................... 64
3.13.1 X drive ........................................................................................ 64
3.13.2 Y drive ........................................................................................ 65
3.14 Checking the play between the toothed rack and gear pinion.... 66
3.15 Setting the configuration set ....................................................... 66
3.15.1 Setting the transfer plate inclination and downforce pressure.... 67
3.15.2 Setting the transfer plate height.................................................. 69
3.15.3 Setting the inner slider inclination and downforce pressure ....... 70
3.15.4 Setting the outer frame inclination .............................................. 72
3.16 Testing inputs and outputs ......................................................... 73
3.16.1 Testing the sewing motor ........................................................... 75
3.16.2 Setting stroke position ................................................................ 77
3.17 Initializing the controller, performing updates ............................. 78
3.17.1 Initializing the controller .............................................................. 79
3.17.2 Initializing the control panel ........................................................ 79
3.17.3 Updating the controller ............................................................... 80
3.17.4 Displaying software version information ..................................... 81
3.18 Customer Service ....................................................................... 81
4 Maintenance.............................................................................. 83
4.1 Maintenance plan ....................................................................... 83
4.2 Lubrication .................................................................................. 84
4.2.1 Central oil lubrication system...................................................... 85
4.2.2 Hook lubrication.......................................................................... 86
4.2.3 Clean and lubricate linear guide of the material feeder .............. 87
4.2.4 Lubricate Y-carriage linear guide................................................ 89
4.2.5 Lubricate stacker linear guide..................................................... 90
4.2.6 Clean and lubricate inner slider .................................................. 91
4.3 Pneumatic system ...................................................................... 95
4.3.1 Setting operating pressure ......................................................... 95
4.3.2 Draining the water condensation ................................................ 96
4.3.3 Cleaning the filter element.......................................................... 97
4.4 Cleaning work............................................................................. 98
4.4.1 Cleaning the machine................................................................. 98
4.4.2 Cleaning the motor fan mesh ..................................................... 99
4.5 Checking the toothed belt......................................................... 100
4.6 Setting the material feeder linear drive..................................... 100
4.7 Setting the hanger movements on the stacker ......................... 102
4.8 Setting the clamp movements .................................................. 103

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Service manual 906 - 00.0 - 11/2014 3
5 Troubleshooting ..................................................................... 105
5.1 Error messages ........................................................................ 105
5.2 Information messages .............................................................. 109
6 Appendix ................................................................................. 111
6.1 Pneumatic circuit diagram ........................................................ 111
6.2 Wiring diagram ......................................................................... 113

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4Service manual 906 - 00.0 - 11/2014

About these Service Instructions
Service manual 906 - 00.0 - 11/2014 5
1 About these Service Instructions
This service instructions for the 906 CNC sewing unit has been compiled
with the utmost care. It contains information and notes to enable the ma-
chine to give many years of reliable service.
Please contact us if you find any discrepancies or have any suggestions
3.18 Customer Service.
Consider this service instructions part of the product and keep it on hand
at all times. Be sure to read the service instructions completely before us-
ing the product for the first time. If you pass the product on to someone
else, please be sure to give them the service instructions.
1.1 Scope of the service instructions
This service instructions describes the set-up and intended use of the
906 CNC sewing unit.
1.2 For whom is this service instructions intended?
This service instructions is intended for:
• Technicians:
This group has the appropriate technical training for performing
maintenance on the sewing machine or repairing malfunctions.
With regard to minimum qualifications and other requirements to be met
by the personnel, please also observe 2 Safety.
1.3 Representation conventions – symbols and characters
Various information in this service instructions is represented or highlight-
ed by the following characters in order to facilitate easy and quick under-
standing:
Correct setting
Indicates proper setting.
Malfunctions
Specifies the faults that can occur due to an incorrect setting.
Cover
Specifies which covers have to be removed in order to access the compo-
nents going to be set.

About these Service Instructions
6Service manual 906 - 00.0 - 11/2014
Steps to be performed when operating the machine
(sewing and equipping)
Steps to be performed for servicing, maintenance, and installation
Steps to be performed via the software control panel
The individual steps are numbered:
1. First step
2. Second step
The sequence of the steps must always be followed.
Lists are identified by bullet points.
Result of performing an operation
Change to the machine or in the display.
Important
Special attention must be paid to this point when performing a step.
Information
Additional information, e.g. on alternative operating possibilities.
Order
Specifies the work to be performed before or after a setting.
References
 Reference to another section in the manual.
Safety Important warnings for the machine operator are specially designated.
Since safety is of particular importance, hazard symbols, levels of danger
and their signal words are described separately in 3 Safety Information.
Orientation If the figure is unclear, indications of "right" and "left" are always from the
operator's point of view.
1.4 Other documents
This equipment includes components from other manufacturers. Each
manufacturer has performed a hazard assessment for these purchased
parts and confirmed their design compliance with applicable European
and national regulations. The proper use of these components is de-
scribed in each manufacturer's manual.
1.
2.
•


About these Service Instructions
Service manual 906 - 00.0 - 11/2014 7
1.5 Liability
All information in this service instructions was compiled with consideration
to the state of the art, and applicable standards and regulations.
The manufacturer cannot be held liable for damages resulting from:
• Breakage and transport damages
• Failure to observe the service instructions
• Improper use
• Unauthorized modifications to the machine
• Use of untrained personnel
• Use of unapproved replacement parts
1.5.1 Transport
Dürkopp Adler cannot be held liable for breakage and transport damages.
Inspect the delivery immediately upon receiving it. Report any damage to
the last transport manager. This applies even if the packaging is undam-
aged.
Leave machines, equipment and packaging material in the condition in
which they were found when the damage was discovered. This will ensure
any claims against the transport company.
Report all other complains to Dürkopp Adler immediately after receiving
the product.
1.5.2 Proper use
The Dürkopp Adler 906 CNC sewing unit is used for sewing pre-bound
pockets. The material requires a needle strength of 120 - 140.
The machine is intended only for use with dry sewing material. The mate-
rial must not contain any hard objects.
The seam is created with thread made of textile fibers (cotton threads,
synthetic threads/core-spun threads).
The sewing unit is intended for industrial use.
The machine may only be set up and operated in dry conditions on well-
maintained premises. If the machine is operated on premises that are not
dry and well-maintained, then further measures may be required which
must be compatible with EN 60204-31:1999.
Only authorized/trained personnel may operate the machine.
The manufacturer cannot be held liable for damages resulting from
improper use.

About these Service Instructions
8Service manual 906 - 00.0 - 11/2014
WARNING
Risk of electric shock, crushing and punctures!
Improper use can result in injury.
Be sure to observe all instructions in the manual.
NOTE
Improper use can result in material damage.
Be sure to observe all instructions in the manual.

Safety
Service manual 906 - 00.0 - 11/2014 9
2 Safety
This section contains basic information for your safety. Read the instruc-
tions carefully before setting up or operating the machine. Make sure to
follow the information included in this section. Failure to do so can result
in serious injury and damage to the machine.
2.1 Basic safety instructions
The machine may be used only as described in the operating instructions.
The operating instructions should be available at the machine's location at
all times.
Work on live components and equipment is prohibited. Exceptions are de-
fined in the specifications in DIN VDE 0105.
For the following work, the machine must be disconnected from the power
supply using the main switch or by disconnecting the power plug:
• Replacing the needle or other sewing tools
• Leaving the workplace
• Performing maintenance work and repairs
• Threading
Missing or faulty spare parts could impair safety and damage the machine.
Make sure you only use original replacement parts from the manufacturer.
Transport Use a sturdy lifting carriage or forklift for transporting the machine. Raise
the machine max. 20 mm and secure it against slipping off.
Installation The power cable must have a plug authorized for the country in which the
machine is being used. The power plug may only be connected to the
power cable by a qualified specialist.
Operator's
obligations
Observe the country specific safety and accident prevention regulations
and the legal regulations concerning industrial safety and the protection of
the environment.
All warnings and safety signs on the machine must always be in legible
condition and may not be removed. Missing or damaged labels should be
replaced immediately.
Requirements
to be met by the
personnel
The machine may only be set up by qualified technicians.
Maintenance work and repairs may only be carried out by qualified tech-
nicians.
Work on electrical equipment may only be carried out by qualified special-
ists.

Safety
10 Service manual 906 - 00.0 - 11/2014
Only authorized persons may work on the machine. Every person who
works on the machine must first have understood the operating instruc-
tions.
Operation Inspect the machine while in use for any externally visible damage. Stop
working if you notice any changes to the machine. Report any changes to
your supervisor. A damaged machine must no longer be used.
Safety equipment Safety equipment should not be removed or deactivated. If this cannot be
avoided for a repair operation, the safety equipment must be refitted and
put back into service immediately afterwards.
2.2 Signal words and symbols used in warnings
Warnings in the text are distinguished by color bars. The color scheme is
oriented towards the severity of the danger. Signal words indicate the de-
gree of risk:
Signal words Signal words and the hazard that they describe:
Symbols The following symbols indicate the type of risk to personnel:
Signal word Hazard
DANGER Will result in serious injury or death.
WARNING Can result in serious injury or death.
CAUTION Can result in minor or moderate injury.
NOTE Can result in property damage.
ATTENTION Environmental damage can result.
Symbol Type of danger
General risk
Risk of electric shock
Risk of puncturing
Risk of crushing

Safety
Service manual 906 - 00.0 - 11/2014 11
Examples Examples of the layout of the warnings in the text:
This is what a warning looks like for a hazard that will result in serious
injury or even death if ignored.
This is what a warning looks like for a hazard that could result in seri-
ous injury or even death if ignored.
This is what a warning looks like for a hazard that could result in mod-
erate or minor injury if the warning is ignored.
Risk of environmental damage
Symbol Type of danger
DANGER
Type and source of risk!
Consequences of non-observance.
Measures for avoiding the risk.
WARNING
Type and source of risk!
Consequences of non-observance.
Measures for avoiding the risk.
CAUTION
Type and source of risk!
Consequences of non-observance.
Measures for avoiding the risk.

Safety
12 Service manual 906 - 00.0 - 11/2014
This is a warning note for a hazard that could result in environmental
damage if ignored.
This is what a warning looks like for a hazard that could result in mate-
rial damage if ignored.
ATTENTION
Type and source of risk!
Measures for avoiding the risk.
NOTE
Type and source of risk!
Measures for avoiding the risk.

Individual settings
Service manual 906 - 00.0 - 11/2014 13
3 Individual settings
3.1 Working basis
3.1.1 Sequence of the settings
The setting positions for the sewing unit are interdependent.
Always adhere to the specified sequence for the individual setting steps.
Always observe all information on requirements and following settings
marked at the side with .
3.1.2 Cable routing
Lay all cables in the machine such that moving parts are not impaired in
their ability to function correctly.
1. Lay any excess cabling neatly in proper cable snakes.
2. Tie the snakes together using a cable tie.
If possible, bind the snakes to fixed parts. The cables must be fixed
firmly in place.
3. Cut off protruding ends of cable ties.
NOTE
Machine damage possible due to incorrect sequence.
Always adhere to the working sequence specified in this manual.
NOTE
Machine damage and malfunctions can be caused by laying the
cables incorrectly.
Excess cabling may obstruct moving machine parts in their ability to
function correctly. This will affect the sewing function and may cause
damage.

Individual settings
14 Service manual 906 - 00.0 - 11/2014
3.1.3 Raising the machine upper section
Important
The drive carriage (2) must be moved to the left stop position.
Figure 1: Move drive carriage to the left stop position
1. Press in the Safe Stop switch (3).
The drive carriage moves to the left stop position.
2. Turn the main switch to the left into the "0" position.
All drives and the controller are disconnected from the mains grid.
Figure 2: Raising the machine upper section
1. Release the locking lever (4) under the table plate.
2. Lift the machine upper section in the head cover region (1) and raise
carefully.
The latch (5) latches into place.
The space under the machine table is now accessible.
WARNING
Risk of injury from sharp or moving parts.
Switch off the sewing unit at the main power switch
before raising the machine upper section and per-
forming maintenance work.
(1) - Head cover
(2) - Drive carriage
(3) - Safe Stop switch
③
①
②
(4) - Locking lever (5) - Latch
④
⑤

Individual settings
Service manual 906 - 00.0 - 11/2014 15
3.1.4 Lowering the machine upper section
Figure 3: Lowering the machine upper section
1. Hold the machine upper section in the head cover region.
2. Release the latch (2).
3. Carefully lower the machine upper section.
4. Latch the locking lever (1) under the table plate.
WARNING
Risk of injury from sharp or moving parts.
Switch off the sewing unit at the main power switch
before lowering the machine upper section and
performing maintenance work.
NOTE
Danger of machine damage from falling machine upper section.
Hold the upper section firmly when lowering until it is once more in
position.
(1) - Locking lever (2) - Latch
②
①

Individual settings
16 Service manual 906 - 00.0 - 11/2014
3.1.5 Removing and fitting the arm cover
Figure 4: Removing and fitting the arm cover
Removing the arm cover
1. Unscrew the motor cover (1).
2. Loosen the screws (2).
3. Remove the arm cover (3).
Fitting the arm cover
1. Fit the arm cover (3).
2. Tighten the screws (2).
3. Tighten the screws for the motor cover (1).
3.1.6 Removing and fitting the head cover
Removing the head cover
1. Loosen the screws (1).
2. Remove the head cover (2).
Fitting the head cover
1. Fit the head cover (2).
2. Tighten the screws (1).
(1) - Motor cover (2) - Screws
(3) - Arm cover
③
①②
(1) - Screws (2) - Head cover
②
①

Individual settings
Service manual 906 - 00.0 - 11/2014 17
3.1.7 Removing and fitting the rear cover
Figure 5: Removing and fitting the rear cover
Removing the rear cover
1. Undo all 3 screws (1).
2. Take off the rear cover (2) by moving it back.
Fitting the rear cover
1. Fitting the rear cover (2).
2. Tighten all 3 screws (1).
3.1.8 Opening and closing the bobbin flap
Bobbin flap open
1. Switch the machine on and reference it.
2. Press the Safe Stop button.
The drive carriage moves to the left stop position.
3. The bobbin flap swings aside.
Closing the bobbin flap
1. Release the Safe Stop button.
The machine is ready for use again.
(1) - Screws (2) - Rear cover
①
②

Individual settings
18 Service manual 906 - 00.0 - 11/2014
3.1.9 Flats on shafts
Some shafts have flats at those points where the components are
clamped on to the shaft. This stabilizes the connection and makes adjust-
ment easier.
Important
The screws must lie completely on the surface. If there are several screws,
the first screw in the direction of rotation must be firmly in place on the sur-
face.
Figure 6: Flats on shafts
3.1.10 Locking the machine in place
For some settings, the machine has to be locked in place. To do this, the
locking peg from the accessory pack is inserted into a groove on the arm
shaft crank to block the arm shaft.
Figure 7: Locking peg and arresting grooves on the arm shaft crank
There are 2 securing positions:
•Position 1: Loop stroke position
• 5 mm end in the large groove
• Setting the loop stroke and needle bar height
•Position 2: Needle at top dead center
• 3 mm end in the small groove
• Checking the top dead center of the needle bar
(1) - Surface (2) - Shaft
(1) - Locking peg
(2) - Large arresting groove
(3) - Small arresting groove
(4) - Arm shaft crank
2
1
④
③
②
①