Dürkopp Adler 838, Service Instructions Manual

Page 1: ...838 Service Instructions ...

Page 2: ...d 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 2015 ...

Page 3: ...r all subclasses of the machine and contains also the instructions for setting optional accessories of the machine if this is necessary owing to their complexity Provided the machine supplied does not contain some elements then the respective chapters may be ignored The succession of the setting operations is expressed here by sequencing the paragraphs of this booklet When setting check up if the ...

Page 4: ...ersons 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...

Page 5: ... the feed clutch 14 2 8 Checking the switch over of the feed clutch 15 2 9 Feed dog 16 2 10 Balance weight 17 3 Top feed 3 1 Position of the needle holder for single needle sewing machines 19 3 2 Needle bar holder 20 3 3 Top roller 22 3 4 Lifting the top roller 23 3 5 Fabric holder for double needle sewing machines 24 4 Setting the needle bar and the hook 4 1 Hook height 25 4 2 Needle bar height p...

Page 6: ...Index Page 7 Electronic control and sewing machine drive positioning motor 36 7 1 Terminals to PCB connections electromagnetic variant 37 7 2 Terminals to PCB connections pneumatic variant 38 ...

Page 7: ...r Please observe that various setting positions are dependent on each other Thus it is essential that the settings be conducted while keeping to the order described For all adjustments of parts involved in the stitch formation a new undamaged needle must be inserted This text does not specifically mention any machine covers or panels which must be removed or re mounted in order to conduct inspecti...

Page 8: ...e needle bar is at top dead centre the pointer 3 should be aligned with 0 degrees 1 2 1 Sewing machines with minimotor Loosen the handwheel screws with a 3 mm Allen key 1 Position the needle bar in the upper dead centre position Use the retention pin 3 mm diameter to peg the position 2 Turn the handwheel so that the pointer 3 points to 0 degrees on the rotary scale Tighten the first screw with the...

Page 9: ...ing pin 2 which is a part of the sewing machine accessories and which is fixed on the oil tray bottom side into the crank head Loosen two setting screws of the hand wheel flange 4 with the Allen key 3 mm 1 Turn the hand wheel flange with the hollow 6 against the sign 3 Tighten both setting screws with the key 1 and fix the hand wheel on again 7 EN 2 4 1 3 6 5 ...

Page 10: ... a 10 mm open ended wrench Verify that the stitch regulator gear is without motion by pressing down on the bartacking lever This fulfils rule 1 Set the scaling ring 4 with stitch length 0 to align with the circular mark 5 Limit the stitch length according to rule 2 For this screw the retention pin 6 into the proper hole The holes are marked with numbers which indicate the maximum stitch length Put...

Page 11: ... and turn the grooved 3 eccentric tappet 2 according to the illustration Fasten with screw 1 Loosen screw 4 on the clamping lever Turn the settings frame 5 so that the shackles 6 are parallel Tighten screw 4 This then fulfils rule 1 The next step is to match up the forwards and reverse stitch lengths Sew ten stitches forwards Press the bartacking lever and then sew ten stitches backwards Rotate th...

Page 12: ...rew 1 Loosen screws 2 Screw out the screw on the feed clutch 4 Push the needle 3 into this opening Turn the clutch 4 with your hand until the needle 3 is 5 mm into the hole The rule is then fulfilled Tighten screw 1 Caution Risk of Injury Turn the main switch off Only carry out this lever adjustment when the machine is turned off ATTENTION Danger of breakage With large stitch lengths it is possibl...

Page 13: ...pet 3 so that it is approximately in the position shown in the illustration Now make the fine scale adjustment to the eccentric tappet Continue until you have found the position where the feed lever 1 no longer moves when the bartacking lever is pressed down Tighten screws at eccentric tappet 3 Caution Risk of injury Turn the main switch off Only carry out this eccentric adjustment when the machin...

Page 14: ...uld be flush with the ridge on the crankshaft 4 Turn the handwheel so that the pointer indicates 239 Loosen screws 1 Insert a settings pin 2 into the eccentric tappet 3 Position it so that it is flush with the crankshaft ridge Tighten screws 1 Caution Risk of injury Turn the main switch off Only carry out this eccentric adjustment when the machine is turned off 12 2 1 3 4 ...

Page 15: ... until you feel it strike the tightening increases in jumps Push the clutch 6 to the right until the end stop is reached Tighten the screws 4 Verify the adjustment Turn the eccentric tappet with your hand in the other direction The resistance during the rotation of the eccentric tappet should increase significantly when the two dashes are lined up Caution Risk of injury Turn the main switch off On...

Page 16: ...od Loosen screws 3 Turn the handwheel to position 305 Turn the eccentric tappet in the direction of arrow so that dash 1 is lined up with dash 2 Turn back the eccentric tappet about 2 and move axially on the shaft until the middle is between the limit settings Align the two dashes 1 and 2 again Tighten the screws 3 Caution Risk of injury Turn the main switch off Only carry out this adjustment when...

Page 17: ...ional direction B of the belt pulley 1 corresponds to the direction specified in the table Do the same for 276 degrees If the rotational directions do not correspond to those specified in the table correct the necessary settings If the clutch switches over too soon on a smaller angle tentatively loosen the adjusting nut 5 see chapter 2 6 and repeat the check Continue loosening until you locate the...

Page 18: ... throat plate must be appropriate for the thickness and toughness of the material 2 In its highest position A the feed dog should be 1 mm over the throat plate insert Loosen screw 1 According to the above rule lower or raise the feed dog Then re tighten screw 1 16 A 1 ...

Page 19: ...len key 3 stuck in stands parallel to the bed plate 2 Loosen the screws on the balance weight 1 Turn the balance weight 1 according to the rule Tighten the screws on the balance weight 1 Caution Danger of injury Turn the main switch off Check and set the balance weight only with the sewing machine switched off 17 EN 1 3 2 ...

Page 20: ...Notes 18 ...

Page 21: ...ity of the needle holder Needle width Nm 120 160 180 200 Loosen screw 1 Turn the needle bar with the right grooved edge 2 on the needle bar axis in the sewing direction Tighten screw 1 Move the needle bar into the top dead centre point Use the 2 5 mm hexagon socket wrench 4 to loosen the needle holder screw in the hole 3 Turn the needle holder 5 according to the rule above Tighten the screw 1 19 E...

Page 22: ...he needle is moved A 0 1mm to the left to the middle of the stitch hole 2 2 for the double needle machine it should be set so the needle stands symmetric to the middle of the stitch hole 3 The needle position is to be adjusted so that the needle is at the rear edge of the stitch hole Loosen screws 1 and adjust the needle bar to the dimension B 31mm as show in the illustration Rule 1 has been fulfi...

Page 23: ... Loosen screw 2 and the two screws 3 Move the post bed feed 4 so that either rule 2 1 is met A 0 1 mm according to Figure 1 or rule 2 2 according to Figure 2 21 EN 3 Fig 1 Fig 2 A 4 2 ...

Page 24: ...ler should be set so that the lower edge of the top roller is aligned with the left edge of the stitch hole 8 Loosen screws 1 Push the presser foot bar perpendicularly according to rule 1 Insert the cross head screwdriver 2 included with the accessories into the hole on the top roller holder 3 Turn the presser foot bar 4 with top roller holder 3 until the screwdriver is at a right angle to the mac...

Page 25: ...osition shown At the same time screw in the screw 3 until it hits the lever 4 The lever 2 remains in the position shown Position the spacer 5 6 mm below the top roller Move the hand lever 5 to the end stop as shown in the illustration Tighten the screws 1 Rule 1 has been fulfilled Using screw 3 set the ventilation cylinder lift for the pneumatic cylinder according to rule 2 The set value is also v...

Page 26: ...abric holder 3 vertically until it comes to rest without any pressure on the leather Tighten screw 1 but not too hard Loosen screw 4 and effectuate the same setting for the front fabric holder 5 Remove the leather rule 1 is now accomplished Set the fabric holder according to rule 2 Set the rear fabric holder 3 to the sewing direction by using screw 6 and laterally by turning the holder 2 Set the f...

Page 27: ...ft the hook at the distance A and tighten the screws 2 Push the ring 3 until its stops at the the hook bottom and tighten screw 1 When replacing the hook it is not necessary to readjust its setting in height again Caution Danger of injury Turn the main switch off Proceed with the hook setting only with the sewing machine switched off 25 EN A 3 1 2 ...

Page 28: ... that the pointer indicates 205 Loosen screws 1 Turn the hook tip 2 on the needle axis Loosen screw 3 Position the needle bar with the needle to the dimension A Tighten screw 3 Loosen two screws 4 and screw 5 Move the hook column 6 from the needle Tighten screws 4 gently With the help of screw 7 move the hook column 6 to the clearance distance B Tighten screws 4 and 5 Verify that the hook tip 2 is...

Page 29: ... Dismount the throat plate Bend the loop former 1 to have the distance A according to rule 1 Turning the screw 2 set the guard 3 so that it prevents the needle being caught with the hook point 4 Check in pushing the needle at the spot of the arrow with simultaneous turning the hook The setting is not incorrect if the guard plate 3 slightly deflects the needle Caution Danger of injury Turn the main...

Page 30: ...be 0 8 mm Insert the retention pin 1 in the lifting cam 2 This is at the rear for the right hook column and at the front for the left hook column Remove the lower plug Loosen screw 3 Adjust the handwheel according to rule 1 Tighten screw 3 Turn the handwheel so the indicator points to 312 Remove the plug Loosen screw 4 Turn the bobbin house lift 5 so that the available clearance distance A complie...

Page 31: ...ng fitting 2 to the distance measure A according to rule 1 and tighten screw 1 This procedure accomplishes rule 1 Screw in screw 3 according to rule 2 In order to throttle the lubrication screw in deeper the screw 3 but not any further than 0 5 mm below the surface of the lubricating fitting 2 Caution Danger of injury Turn the main switch off Proceed with the setting of the hook lubrication only w...

Page 32: ...to number 4 according to rule 1 Tighten screw 2 Loosen screw 3 Turn stop sleeve 4 in the direction of arrow until the thread take up lever 5 is separated from the body 6 Turn the stop sleeve 4 in the opposite direction as the arrow Turn until the thread take up lever touches the body 6 Turn both parts 4 and 6 together until the clearance distance A is reached Hold the body 6 tight while turning th...

Page 33: ...ley to the top using the screws 1 Push the toothed belt to the right so that both screws 1 are accessible Loosen screws 1 and set the distance measure A according to rule 1 tighten screws 1 Determine the bobbin filling by adjusting screw 2 Screw in screw 2 for 1 to 2 mm but a bobbin on the bobbin winder shaft and wind on thread Check the filling level as soon as the bobbin winder turns off If nece...

Page 34: ...its on the surface of the shaft Tighten screw 3 until the distance measure A 0 2 mm is set and thus rule 1 is accomplished Tighten screw 2 and afterwards also screw 1 Dismount the column protection Loosen screws 7 and 4 Set the distance measure B 0 3 to 0 5 mm according to rule 2 Slightly tighten screw 4 Turn the handwheel so that the index points to degree 270 Turn the thread pulling knife 5 manu...

Page 35: ...blade of the counter knife 4 of 0 5 1 mm Check whether the control cam 2 butts against the ring 5 Position the control cam according to the rule Loosen screw 6 Set the thread pulling knife 3 according to the rule Tighten screw 6 Caution Danger of injury Turn the main switch off Proceed with the thread cutter setting only with the sewing machine switched off 33 EN 1 5 2 6 4 3 ...

Page 36: ... distance between the cam and the roller is A 0 05 0 1 mm Shift the ring 3 to the right towards the cam 1 until it stops Take care that the hook timing par 4 2 is not destroyed Tighten the ring 3 screws Tighten the cam 1 screws so that the trimming knife 4 edge and the fixed knife 5 edge flush at 40 45 on the hand wheel Check the setting of the distance according to rule 1 cam angle according to r...

Page 37: ...spect the thread according the illustration Check if the thread is being pulled out of the bobbin winder or from the clamping 1 Using screw 3 control and adjust the spring pressure 1 until the rule is fulfilled Caution Risk of injury Turn the main switch off Only adjust the clamping spring when the machine is turned off CAUTION Sewing problems can result when the clamping spring is improperly adju...

Page 38: ...n electronic components Turn off the main switch Remove the plug from the socket Electrostatic discharges can cause damage to PCBs and other components You can obtain a certain protection by wearing anti static gloves or wrist wraps that you can connect for grounding on the mass of any unpainted metal piece of the machine head or on the switch cabinet Handle the PCBs with utmost caution They are v...

Page 39: ...nnecting cable 9870 688002 for connector on base plate thread trimmer solenoids sewn material edge horizontal trimmer X17 microswitch of sewn material edge trimmer vertical oblique X18 sewn material edge trimmer motor F1 sewn material edge trimmer resettable fuse R1 Autoselect resistor sewing machine class selection S11 tilt sensor J1 switch if the sewing machine has a direct drive DAC control sid...

Page 40: ...DB3000 needle switch off 10 0V FW STL FA auxiliary outlet thread wiper zero stitch length at thread trimming X20 external outlet controlled with auxiliary pushbutton on keypad Imax 50mA X21 connection of auxiliary cable for bottom distribution FA 24V GND X22 external blocking of operation e g thread lever guard switch etc X23 connection of a side DAC switchboard direct drive X24 material edge trim...

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Page 42: ... Germany Phone 49 0 521 925 00 E Mail service duerkopp adler com www duerkopp adler com Subject to design changes Part of the machines shown with additional equipment Printed in Germany Dürkopp Adler AG Service Instructions 0791 838640 EN 01 0 09 2015 ...