DURKOPP ADLER H-Type 969 Service Instructions Manual
969
Service Instructions
All rights reserved.
Property of Dürkopp Adler AG and protected by copyright. Any reuse of these contents,
cluding extracts, is prohibited without the prior written approval of Dürkopp Adler AG.
in
Copyright © Dürkopp Adler AG - 2015
Table of Contents
1 About these Service Instructions..............................................3
1.1 Scope of the Service Instructions.................................................3
1.2 Representation conventions – symbols and characters...............3
1.3 Other documents..........................................................................4
1.4 Liability..........................................................................................4
2 Safety...........................................................................................5
2.1 Basic safety instructions...............................................................5
2.2 Signal words and symbols used in warnings................................6
3 Basic Principles of Working with the Machine........................9
3.1 Sequence of the settings..............................................................9
3.2 Cable routing................................................................................9
3.3 Removing the covers..................................................................10
3.3.1 Access to the underside of the machine.....................................10
3.3.2 Removing and fitting the arm cover............................................11
3.3.3 Removing and fitting the head cover..........................................12
3.3.4 Removing and fitting the cover plate..........................................12
3.3.5 Removing and fitting the handwheel and belt cover...................13
3.3.6 Removing and installing the thread tension plate.......................13
3.3.7 Removing and installing the hook compartment cover...............14
3.3.8 Removing and installing the throat plate .................................... 15
3.3.9 Removing and installing the feed dog ........................................ 16
3.4 Flats on shafts ............................................................................17
3.5 Axial play for shafts running in plain bearings............................18
3.6 Locking the machine in place.....................................................19
3.7 Moving the handwheel into position ........................................... 20
4 Positioning the arm shaft.........................................................21
5 Setting the handwheel scale ...................................................23
6 Setting the drive .......................................................................25
6.1 Setting the drive ratio..................................................................25
6.1.1 Removing the belt.......................................................................25
6.1.2 Adjusting the drive pulley............................................................26
6.1.3 Adjusting the belt tension ...........................................................27
6.2 Adjusting the positioning of the machine....................................28
6.2.1 Determining the drive ratio in the control program......................28
6.2.2 Adjusting the reference position of the handwheel.....................28
7 Setting the stitch length adjusting wheels............................. 31
7.1 Setting the upper stitch length adjusting wheel.......................... 31
7.2 Setting the lower stitch length adjusting wheel...........................33
7.3 Setting the stitch length limit.......................................................35
7.4 Setting the eccentric for the forward and backward stitches......37
8 Setting the feed dog.................................................................39
8.1 Setting the feed dog position......................................................39
8.1.1 Moving the feed dog...................................................................40
8.1.2 Moving the feed dog carrier........................................................40
8.2 Setting the feed dog movement..................................................42
8.2.1 Adjusting the forward movement................................................42
Service Instructions 969 - 01.0 - 12/2015
1
Table of Contents
8.2.2 Setting the feed dog height at top dead center...........................43
8.2.3 Setting the stroke movement......................................................44
9 Aligning the needle bar linkage...............................................47
9.1 Moving the needle bar linkage sideways....................................47
9.2 Aligning the needle bar linkage in the sewing direction..............49
10 Position of the hook and needle .............................................51
10.1 Tensioning the hook drive toothed belt.......................................51
10.2 Adjusting the dead center of the reciprocating movement of
the driver.....................................................................................52
10.3 Setting the loop stroke position .................................................. 53
10.4 Setting the hook clearance.........................................................54
10.5 Adjusting the loop former............................................................55
10.6 Setting the needle bar height......................................................56
11 Adjusting the sewing foot feed ...............................................59
11.1 Adjusting the zero stroke of the feet, tension force of the
torsion spring..............................................................................59
11.2 Adjusting the drive dog for the presser foot bar..........................60
11.3 Aligning the feed stroke of the feet.............................................61
11.4 Setting the stroke movement for the feeding foot.......................62
12 Adjusting the foot stroke.........................................................65
12.1 Adjusting the foot stroke using the hand lever............................65
12.2 Adjusting the foot stroke using the pneumatic cylinder...............66
13 Adjusting the thread system ...................................................67
13.1 Setting the thread tensioning spring........................................... 67
13.2 Setting the winder.......................................................................68
13.3 Setting the hook thread guide.....................................................72
14 Adjusting the thread cutter...................................................... 75
14.1 Adjusting the thread cut-off point................................................75
14.2 Basic setting of the thread cutter................................................76
14.3 Adjusting the position of the movable knife................................ 77
14.4 Adjusting the cutting pressure of the knife..................................78
15 Soft start....................................................................................81
16 Maintenance..............................................................................83
16.1 Cleaning the filter element..........................................................83
16.2 Lubricating the needle bar..........................................................85
2
Service Instructions 969 - 01.0 - 12/2015
About these Service Instructions
1.
2.
etc.
•
1 About these Service Instructions
These instructions for sewing machine 969 have been compiled with the
utmost care. They contain information and notes intended to ensure longterm and reliable operation.
1.1 Scope of the Service Instructions
These instructions describe the setting and maintenance work on the
969 machine. They apply to all submodels.
The intended use and setup is described in the Ope
1.2 Representation conventions – symbols and characters
Various information in these instructions is represented or highlighted by the
following characters in order to facilitate easy and quick understanding:
Proper setting
Indicates proper setting.
rating Instructions.
Malfunctions
Specifies the faults that can occur due to an incorrect setting.
Steps to be performed when operating the machine (sewing and
e
quipping)
Steps to be performed for service, maintenance, and installation
Steps to be performed via the software control panel
The individual steps are numbered:
1. First step
2. Second step
The steps must always be followed in the specified order.
Lists are marked by bullet points.
Result of performing an operation
Change to the machine or display.
Important
Special attention must be paid to this point when performing a step.
Service Instructions 969 - 01.0 - 05/2015
3
About these Service Instructions
Information
Additional information, e.g. on alternative operating options.
Sequence
Specifies the work to be performed before or after a setting.
References
Reference to another section in these instructions.
Safety Important warnings for the machine users are specially designated. Since
safety is of particular importance, hazard symbols, levels of danger and
their signal words are described separately in section 2 Safety.
Orientation If no other clear location markers are used in a diagram, indications of right
or left are always from the operator's point of view.
1.3 Other documents
Some of the machine's built-in components have been made by third-party
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 described in each manufacturer's instructions.
1.4 Liability
All information in these service instructions was compiled in accordance
with the current state of the art and the applicable standards and
regulations.
Dürkopp Adler cannot be held liable for damages resulting from:
• Breakage and damage during transport
• Failure to follow the operating instructions
• Improper use
• Unauthorized modifications to the machine
• Use of untrained personnel
• Use of unapproved replacement parts
4
Service Instructions 969 - 01.0 - 05/2015
Safety
2 Safety
This chapter contains basic information for your safety. Read the instructions carefully before setting up or operating the machine. Always follow
t
he information included in this section. Failure to do so can result in seri-
ous injury and property damage.
2.1 Basic safety instructions
The machine may only be used as described in these instructions.
The instructions should be available at th
Work on live components and equipment is prohibited
e machine's location at all times.
. Exceptions are de-
fined in the DIN VDE 0105.
For the following work, the machine must be disconnected from the power
ly using the main switch or by disconnecting the power plug:
supp
• Replacing the needle or other sewing tools
• Leaving the workstation
• Performing maintenance work and repairs
• Threading
Missing or faulty spare parts could impair safety and damage the machine.
Make sure
Transport Use a sturdy lifting carriage or forklift truck for transporting the machine.
you only use original replacement parts from the manufacturer.
Raise the machine max. 20 mm and secure it to prevent it from slipping
ff.
o
Setup The power cable must have a plug that is authorized for use in the country
in which the machine is being used. The power plug may only be connected to the power cable by qualified specialists.
Obligations
of the operator
Observe the country-specific safety and accident prevention regulations
and the legal regulations concerning industrial safety and the protection of
the environment.
All the warnings and safety signs on the machine must always be in legible
ition, and must not be removed. Missing or damaged labels must be
cond
replaced immediately.
Requirements
to be met by
the personnel
The machine may only be set up by qualified specialists.
Maintenance work and repairs may only be carried out by qualified
pecialists.
s
Work on electrical equipment may only be carried out by qualified
pecialists.
s
Only authorized persons may work on the machine. Every person who
works o
Service Instructions 969 - 01.0 - 12/2015 5
n the machine must first have understood these instructions.
Safety
Operation Inspect the machine for any externally visible damage during use. Stop
working if you notice any changes to the machine. Report any changes to
your supervisor. Machines must no longer be used if they are damaged.
Safety
equipment
Safety equipment should not be removed or deactivated. If it is essential
to remove or deactivate safety equipment for a repair operation, it must be
refitted and put back into service immediately afterward.
2.2 Signal words and symbols used in warnings
Warnings in the text are distinguished by color bars. The color scheme
based on the severity of the danger. Signal words indicate the severity of
the danger.
Signal words Signal words and the hazard that they describe:
Signal word Meaning
DANGER (with hazard symbol)
If ignored, fatal or serious injury will result
WARNING (with hazard symbol)
If ignored, fatal or serious injury can result
CAUTION (with hazard symbol)
If ignored, moderate or light injury can result
NOTICE (without hazard symbol)
If ignored, property damage can result
Symbols The following symbols indicate the type of danger to personnel:
Symbol Type of danger
General
Electric shock
Puncturing
Crushing
Environmental damage
6 Service Instructions 969 - 01.0 - 12/2015
Safety
Examples Examples of the layout of warnings in the text:
DANGER
Type and source of danger!
Consequences of non-compliance.
Measures for avoiding the danger.
This is what a warnin
injury or even death if ignored.
g looks like for a hazard that will result in serious
WARNING
Type and source of danger!
Consequences of non-compliance.
Measures for avoiding the danger.
This is wh
ous or even fatal injury if ignored.
at a warning looks like for a hazard that could result in seri-
CAUTION
Type and source of danger!
Consequences of non-compliance.
Measures for avoiding the danger.
This is what a warn
moderate or minor injury if the warning is ignored.
ing looks like for a hazard that could result in
CAUTION
Type and source of danger!
Consequences of non-compliance.
Measures for avoiding the danger.
This is what
environmental damage if ignored.
Service Instructions 969 - 01.0 - 12/2015 7
a warning note looks like for a hazard that could result in
Safety
NOTICE
Type and source of danger!
Consequences of non-compliance.
Measures for avoiding the danger.
This is what a warning looks like for a hazard that could result in
property damage if ignored.
8 Service Instructions 969 - 01.0 - 12/2015
Basic Principles of Working with the Machine
3 Basic Principles of Working with the Machine
3.1 Sequence of the settings
The setting positions for the machine are interdependent.
Always adhere to the specified sequence for the individual setting steps.
Always observe all the information on requirements and following settings
marked at the side with .
NOTICE
Risk of machine damage due to incorrect sequence.
Always adhere to the working se
instructions.
quence specified in these
3.2 Cable routing
Ensure that all cables in the machine are laid in such a way that they do
not impair the function of the moving parts.
1. Lay any excess cabling neatly in
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 any excess material off the cable tie.
proper cable snakes.
NOTICE
Machine damage and malfunctions can be caused by laying
the cables incorrectly.
Excess cabling may prevent moving ma
correctly. This will affect the sewing operation, and may cause
damage.
Lay excess cabling as described above.
chine parts from functioning
Service Instructions 969 - 01.0 - 12/2015
9
Basic Principles of Working with the Machine
①
3.3 Removing the covers
WARNING
Risk of injury!
Crushing injuries from moving parts.
Switch the machine off before you remove the
cove
rs or refit them.
For many types of setting work, you will have to remove the machine covers in order to access the components.
This section describes how to remove the
The text for each type of setting work then specifies only the cover that
needs to be removed at that particular time.
individual covers and refit them.
3.3.1 Access to the underside of the machine
In order to access the components on the underside of the machine, you
must first swivel up the machine head.
Fig. 1: Tilting and erecting the machine head
Tilting the machine head
1. Push the lever (1) up.
Th
e locking mechanism disengages.
2. Tilt the machine head.
10
Erecting the machine head
1. Tilt the machine head forward.
2
. Pull the lever (1) up again and carefully tilt the machine head back down.
Service Instructions 969 - 01.0 - 12/2015
Basic Principles of Working with the Machine
(1) - Right adjusting wheel
(2) - Left adjusting wheel
(3) - Screws
(4) - Upper left cover
(5) - Upper right cover
(6) - Screws
(7) - Lever
①
②
③
④
⑤
⑥
⑦
3.3.2 Removing and fitting the arm cover
If necessary, each of the two top covers can be removed separately.
Fig. 2: Removing and fitting the arm cover
Removing the left arm cover
1. Turn left adjusting wheel (2) to position 0.
2
. Turn right adjusting wheel (1) to position 8.
The cover cannot be removed unless the adjusting wheels are set to
the proper position.
3. Loosen the screws (3).
4. Lift the upper left cover (4) up in the direction of the arrow.
Removing the right arm cover
1. Turn the lever (7) clockwise as far as it will go.
2
. Loosen the screws (6).
3. Raise the cover and disconnect the power plug for the fan that is attached
to the underside of the cover.
4. Lift the upper right cover (5) up in the direction of the arrow.
Service Instructions 969 - 01.0 - 12/2015
11
Basic Principles of Working with the Machine
(1) - Head cover (2) - Screws
①
②
(1) - Cover plate (2) - Screws
①
②
3.3.3 Removing and fitting the head cover
Fig. 3: Removing the head cover
Removing the head cover
1. Loosen the screws (2).
2. Remove the head cover (1).
3.3.4 Removing and fitting the cover plate
Fig. 4: Removing the cover plate
Removing the cover plate
12
1. Loosen the screws (2).
2
. Remove the cover plate (1).
Service Instructions 969 - 01.0 - 12/2015
Basic Principles of Working with the Machine
(1) - Handwheel fastening screws
(2) - Handwheel
(3) - Belt cover
(4) - Belt cover fastening screws
①
③
④
(1) - Upper right cover
(2) - Thread tension plate fastening
screws
(3) - Thread tension plate
①
③
3.3.5 Removing and fitting the handwheel and belt cover
Fig. 5: Removing the belt cover
Removing the belt cover
1. Loosen the screws (1).
2
. Remove the handwheel (2).
3. Loosen the screws (4).
4. Take off the belt cover (3).
3.3.6 Removing and installing the thread tension plate
Fig. 6: Removing the thread tension plate
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13
Basic Principles of Working with the Machine
(1) - Cover (2) - Screw
③
Removing the thread tension plate
1. Start by removing the upper right cover (1).
As the th
read tension plate is connected to cables and hoses that are
attached below the upper right cover, you will need to remove this cover first.
2. Loosen the screws (2).
3. Take off the thread tension plate (3).
3.3.7 Removing and installing the hook compartment cover
Fig. 7: Removing the hook compartment cover
Removing the hook compartment cover
1. Push in the cover (1) at position (3).
2
. Turn the cover (1) clockwise.
3. Loosen the screw (2).
4. Remove the cover (1).
14
Service Instructions 969 - 01.0 - 12/2015
Basic Principles of Working with the Machine
(1) - Throat plate (2) - Screws
①
②
3.3.8 Removing and installing the throat plate
WARNING
Risk of injury!
Risk of crushing injuries and stab wounds from
sharp
Switch the machine off before you remove or install
th
Fig. 8: Removing and installing the throat plate
and moving parts.
e throat plate.
Removing the throat plate
1. Raise the sewing feet.
2
. Loosen the screw (2).
3. Remove the throat plate (1).
Service Instructions 969 - 01.0 - 12/2015
15
Basic Principles of Working with the Machine
(1) - Feed dog carrier
(2) - Screws
(3) - Feed dog
②
③
3.3.9 Removing and installing the feed dog
WARNING
Risk of injury!
Risk of crushing injuries and stab wounds from
sharp
Switch the machine off before you remove or install
th
Fig. 9: Removing and installing the feed dog
and moving parts.
e feed dog.
16
Removing the feed dog
1. Remove the throat plate ( p
. 15).
2. Loosen the screws (2).
3. Take the feed dog (3) off the feed dog carrier (1).
Installing the feed dog
1. Place the feed dog (3) on the feed dog carrier (1) and lightly tighten the
screws (2).
2
. Install the throat plate ( p. 15)
3. Adjust the feed dog (3) so that it has an equal amount of play on both
sides when inside the throat plate.
4. Tighten the screws (2).
Service Instructions 969 - 01.0 - 12/2015
Basic Principles of Working with the Machine
(1) - Shaft (2) - Surface
①
3.4 Flats on shafts
Fig. 10: Flats on shafts
Some shafts have flat surfaces at the points where the components are
screwed on. This stabilizes the connection and makes adjustment easier.
Always ensure that the screw faces are completely flush with the surface.
Service Instructions 969 - 01.0 - 12/2015
17
Basic Principles of Working with the Machine
(1) - Plain bearing shell
(2) - Shaft
(3) - Lever
(4) - Adjusting ring
④
3.5 Axial play for shafts running in plain bearings
Fig. 11: Axial play for shafts running in plain bearings
Shafts (2) running in plain bearing shells (1) are axially adjusted when the
lever (3) and the adjusting ring (4) touch the front face of the bearing
shells (1).
When adjusting components mounted on shafts running in plain bearings,
always ensure that the axial play of these shafts is as small as possible,
or 0.
18
Service Instructions 969 - 01.0 - 12/2015
Basic Principles of Working with the Machine
(1) - Slot
(2) - Arresting pin
(3) - Locking opening
①
②
③
3.6 Locking the machine in place
For some settings, the machine has to be locked in place. To do this, the
arresting pin from the accessory pack is inserted into a slot on the arm
shaft crank, blocking the arm shaft.
There are 2 securing positions:
• Posi
• Posi
Fig. 12: Locking the machine in place
tion 1: Loop stroke position
• 5 mm end in the large slot
•
Setting the loop stroke and needle bar height
tion 2: Handwheel zero position
• 3 mm end in the small slot
•
Setting the handwheel position and checking the bottom dead cen-
ter for the needle bar
Locking the machine in place
1. Turn the handwheel until t he appropriate slot (1) is in front of the locking
op
ening (3):
• Small slot at handwheel position 180°
• Large slot at handwheel position 200 – 205°
2. Insert the corresponding end of the arresting pin (2) into the slot (1).
Removing the positional lock
1. Pull the arresting pin (2) out of the slot (1).
Service Instructions 969 - 01.0 - 12/2015
19
Basic Principles of Working with the Machine
①
②
(1) - Graduated scale (2) - Marking
3.7 Moving the handwheel into position
For some settings, the graduated scale on the handwheel has to be
moved to a certain position.
Fig. 13: Moving the handwheel into position
Setting steps
1. Turn the handwheel until the specified number on the graduated
scale
(1) is next to the marking (2).
20
Service Instructions 969 - 01.0 - 12/2015
Positioning the arm shaft
(1) - Setscrews
①
4 Positioning the arm shaf t
Proper setting
The 3 setscrews (1) are seated flush on
flush with the machine casting.
Cover
• Upper left cover, ( p. 11).
WARNING
Risk of injury!
Crushing injuries from moving parts.
Switch the machine off before you check and set
th
e position of the arm shaft crank.
the flat. The arm shaft crank is
Fig. 14: Setting the arm shaft crank
Setting steps
1. Loosen all the setscrews (1) on the arm shaft crank.
2
. Turn the arm shaft crank so that the setscrews (1) are seated flush on
the flat of the arm shaft.
3. Push the arm shaft to the right as far as it will go, un til it is flush with the
machine casting.
4. Tighten all the setscrews (1) on the arm shaft crank.
Service Instructions 969 - 01.0 - 12/2015
21
Positioning the arm shaft
22
Service Instructions 969 - 01.0 - 12/2015
Setting the handwheel scale
(1) - Screws
(2) - Handwheel
(3) - Opening for the hex key
①
②
③
5 Setting the handwheel scale
Proper setting
Lock the machine in place at position 2 ( p. 19).
Th
e handwheel is at the 180° position.
Cover
• Remove handwheel and belt cover ( p. 13).
Fig. 15: Setting the handwheel scale
WARNING
Risk of injury!
Crushing injuries from moving parts.
Switch the machine off before you check and set
th
e position of the handwheel on the arm shaft.
Setting steps
1. Remove the belt cover and handwheel (
drive belt ( p. 25).
2. Loosen the screws (1).
3. Install the belt cover and handwheel.
4. Lock the machine in place at position 2 ( p. 19).
5. Set the handwheel (2) to 180° position ( p. 20).
6. Slide the hex key through the opening (3) and into the adjusting screw,
then tighten the screw.
7. Remove the belt cover and handwheel ( p. 13).
8. Tighten the screws (1).
9. Install the ridged drive belt together with the belt cover and handwheel.
Service Instructions 969 - 01.0 - 12/2015
p. 13), and take off the ridged
23
Setting the handwheel scale
24
Service Instructions 969 - 01.0 - 12/2015
Setting the drive
(1) - Ridged drive belt
(2) - Tensioning roller
(3) - Belt tensioner
(4) - Belt tensioner screws
①
②
③
④
6 Setting the drive
6.1 Setting the drive ratio
WARNING
Risk of injury!
Crushing injuries from moving parts.
Switch off the machine before checking and setting
th
e drive transmission ratio.
The machine is equipped with a 2-step pulley, which can be used to adjust
the drive ratio between the drive motor and the machine, and increase the
penetration force of the needle.
In order to change the ratio, the drive belt must be removed and the pulley
chan
ged to the opposite position. The drive belt is then refitted and
tensioned.
Cover
•Belt cover ( p. 13).
• Handwheel
6.1.1 Removing the belt
Fig. 16: Removing the belt
Service Instructions 969 - 01.0 - 12/2015
Setting steps
1. Loosen the screws (4) on the belt tensioner (3).
2
. Rotate the tensioning roller (2) and belt tensioner (3).
25
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