559

Doppelkettenstich Knopflochautomat
Einfachkettenstich Schnürlochautomat
Automatic double-chainstitch buttonholer
Automatic single-chainstitch eyelet machine

1
Bedienanleitung / Operating Instructions

Aufstellanleitung / Installation Instructions 2

Serviceanleitung / Service Instructions 3

Postfach 17 03 51, D-33703 Bielefeld Ÿ Potsdamer Straße 190, D-33719 Bielefeld

Telefon +49 (0) 5 21/ 9 25-00 Ÿ Telefax +49 (0) 5 21/ 9 25 24 35 Ÿ www.duerkopp-adler.com
Ausgabe / Edition: Änderungsindex Teile-Nr./Part.-No.:
07/2007 Rev. index: 01.0 Printed in Federal Republic of Germany 0791 559001
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 Anleitung, komplett / Manual, complete

559

Übersicht Summary

Bedienanleitung Operating Instructions

Aufstellanleitung Installation Instructions
Serviceanleitung Service Instructions

Bauschaltplan Interconnection-diagram

9890 580001 B 9890 580001 B

Pneumatikgeräteplan Pneumatic circuit plan

9770 559001 9770 559001

Alle Rechte vorbehalten.

Eigentum der Dürkopp Adler AG und urheberrechtlich geschützt. Jede, auch auszugsweise
Wiederverwendung dieser Inhalte ist ohne vorheriges schriftliches Einverständnis der Dürkopp Adler AG
verboten.
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 - 2007

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 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!

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 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.

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 Index Page:

Part 3: Service Instructions Class 559

1. General notes
1.1 Necessary program setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

2. Adjusting the locking positions

2.1 General notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.2 Looper and spreader eccentric . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.3 Rotary thread take-up disc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.4 Throw eccentric . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

3. Needle bar positioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

4. Aligning the looper turret . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

5. Aligning the needle bar parallel to the looper turret . . . . . . . . . . . . . . . . . . . . . . . . 11

6. Transversal motion of the fabric support plate . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

3
7. Longitudinal motion of the fabric support plate . . . . . . . . . . . . . . . . . . . . . . . . . . 15

8. Clamping plates
8.1 Inserted clamping plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
8.2 Aligning the clamping plates as to the fabric support plate . . . . . . . . . . . . . . . . . . . . . . 18
8.3 Adjusting the spreading. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
8.4 Height of the fabric clamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
8.5 Adjusting the locking sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
8.6 Arrest of the clamping plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
8.7 Adjusting the fabric clamping pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

9. Adjusting the seam width

9.1 Presetting the seam width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
9.2 Needle zero position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

10. Cutting knife (Eyelet knife)

10.1 Position of the cutting knife . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
10.2 Adjusting the knife parallel to the cutting block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
10.3 Cutting block adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
10.4 Adjusting the switch for the trimming system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
10.5 Cutting pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
10.6 Cutting duration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

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 Index Page:

11. Looper height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

12. Adjusting the looping stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

13. Needle bar height. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

14. Distance between looper and needle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

15. Needle guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

16. Spreader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

17. Spreader plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

18. Throat plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

19. Adjusting the needle thread knife . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

20. Adjusting the fabric clamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

21. Thread controller spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

22. Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

23. Annex
23.1 Adjusting operations without head cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
23.2 Fuses in the control box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
23.3 Exchange of the control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

24. Service menu (technician level)

24.1 Activating the service menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
24.2 Selection of a menu item/submenu item . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
24.3 Multitest . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
24.4 Quitting the service menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
24.5 List of menu and submenu items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
24.6 Menu items 500 (Configuration automatic buttonholer) . . . . . . . . . . . . . . . . . . . . . . . . 53
24.7 Menu items 520 (Tension data for the needle thread calibration) . . . . . . . . . . . . . . . . . . 54
24.7 Menu items 550 (Configuration operation) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
24.8 Menu items 600 (Multitest) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

25. Error messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

26. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

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 1. General notes
The service manual on hand describes the adjustment of the automatic
buttonholer 559 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!

Caution: 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:

– Switch the main switch off. 3
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 operation 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!

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 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 staking-out position, the rotary thread take-up
disc and the eccentrics for the spreaders, the loopers and the
connecting stitch have to be in staking-out position, too.
The positions have been set by the manufacturer in such a way that
standard material can be sewn with the 559.
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 pegs are included in the accessories of the machine and
have a diameter of 5 mm.

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 2.2 Looper and spreader eccentric

1 6 4 3 2 5

Caution: Danger of injury!

Switch the main switch off.
Adjust the eccentrics only with the sewing machine switched off. 3

Standard checking
When the arm shaft is staked out with arresting pin 1, it should
be possible to stake out the looper eccentric 3 and the spreader
eccentric 4, too.
– Stake out the arm shaft with arresting pin 1.
Important !
In this position the needle bar must be in the top dead center in
front of the left entry point.
– Check with the arresting pin 2 whether the looper eccentric 5 and
the spreader eccentric 6 can be staked out.

Correction
– Stake out the arm shaft with the arresting pin 1.
– Loosen the screws at the looper eccentric 3.
– Turn and stake out the eccentric.
– Tighten the screws.

– Loosen the screws at the spreader eccentric 4.

– Turn and stake out the eccentric.
– Tighten the screws.

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 2.3 Rotary Thread Take-up Disc

2 1

Caution: Danger of injury!

Switch the main switch off.
Adjust the rotary thread take-up disc only with the sewing machine
switched off.

Standard checking
When the arm shaft has been arrested through the arresting pin 2,
so that the looper holder is in the left end position (left entry point),
the rotary thread take-up disc 6 should be in the right position
for a needle 4 that is put on the bore hole of the rotary thread take-up
disc to butt against the right surface 3.

Correction
– Remove the tension plate 1.
– Loosen the screws on the belt pulley 5.
– Push the needle 4 through the bore hole in the rotary thread
take-up disc 6.
6 5 4 3
– Turn the rotary thread take-up disc until the needle 4 butts against
the surface 3.
– Fix the screws on the belt pulley 5 again.

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 2.4 Throw eccentric

4 3 2 1 5

Caution: Danger of injury !

Switch the main switch off. Adjust the rotary thread take-up disc only
with the machine switched off. 3

Standard checking
When the looper turret 5 is in its right end position (right entry point),
the arresting pin 4 inserted in the eccentric 2 should abut in the
notching 1 at the arm.
– Turn the arm shaft in such a way that the looper turret is on the
right side (right entry point).
– Put the arresting pin 4 in the drill-hole 3 of the eccentric 2.
– Check whether the arresting pin 4 abuts in the notching 1 of the
arm.

Correction
– Loosen the screws at the eccentric 2.
– Position the eccentric with the arresting pin right on top against the
arm.
– Tighten the screws at the eccentric 2.

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 3. Needle bar positioning

3 2 1 4 2

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 center. The looper turret is in its
right end position (right entry point) then.
– Switch the machine on.
The machine positions automatically.
– Check whether the needle bar is in the top dead center and
whether the looper turret is in its right end position (right entry
point).

Correction
– Switch the machine on. The machine positions automatically.
– Move the needle bar in the correct position by handwheel (right
entry point).
– Switch to the technician level.
For this purpose press the keys “P” and “ç “ simultaneously.
– Enter code “2548”.
– Press key “OK”.
The control switches to the technician level.
– Select menu “603”.
– Press key “OK”.
– Loosen screw 1 at the switching 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 (inlet r0)
– Tighten the screw 1 at the switching segment 2.
Note:
The switching segment must be in the middle of the light barrier.
– Switch the machine on and check the positioning.

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 4. Aligning the looper turret

2 1 3

Caution: Danger of injury!

Switch the main switch off.
Align the looper turret only with the machine switched off.
3
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 stake out the looper turret 2
with the arresting 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 staked out with arresting
pin 1.

4 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 at the toothed belt wheel with the
hexagonal spanner 3.
– Turn the looper turret in such a way that it can be staked out
with pin 1.
– Tighten the clamping screw with the hexagonal spanner 3.

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 5

10

10

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 5. Aligning the needle bar parallel to the looper turret

Caution: Danger of injury!

Switch the main switch off.
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.
– Stake out the looper turret with arresting pin 2.
– Position an angle 5 at the right side 6 of the looper turret.
– Check whether the screw 7 at the needle bar guide 8 abuts on the
angle.

Correction
– Loosen the screws 9 at the toothed belt wheel 10. 3
– Turn the needle bar guide 4 correspondingly.
– Tighten the screws 9 at the toothed belt wheel 10.
– Switch the machine on.
– Check the needle bar position.

4
1

11

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 X2

1 X1 1

4 3 2

12

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 6. Transversal motion of the fabric support plate

Caution: Danger of injury!

Exercise utmost caution when making adjustments with the machine
running.

Note
Please observe the necessary program setting as described in
chapter 1.1.

Standard checking
The looper turret 3 must be in the center of the fabric support plate 4.
When the automatic buttonholer is in reference position, the
dimensions X1 and X2 must be equal when the fabric support plate is
adjusted correctly.
The distance between reference switch 5 and switch sheet 6 must not
exceed 0.5 mm.
– Switch the machine on.
– Press the keys “P” and “ß” on the control panel simultaneously.
– Enter code “2548”.
– Press key ”OK”.
The control switches to the technician level.
– Select the menu “608” with the key “+”.
– Switch the menu on with key ”OK”.
The machine runs to its initial position.
3
– Switch the machine off.
– Check the dimension X1 with the slide gauge 2 (right edge of the
throat plate groove to the left edge of the fabric support plate).
– Check the dimension X2 (left edge of the throat plate groove to the
right edge of the fabric support plate).

6 5

13

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 7 6 8 5

Correction
– Switch the machine on and press the keys “P” and “ß” on the
control panel simultaneously.
– Enter code “2548”.
– Press key ”OK”.
The control switches to the technician level.
– Select the menu “603” with the key “+”.
In this mode the step motors are dead.
– Switch the menu on with key ”OK”.

Caution: Danger of injury!

Exercise utmost caution when making adjustments with the machine
running.

– Shift the fabric support plate manually in such a way that the
dimensions X1 and X2 are equal.
– Loosen screw 7.
– Turn the switch sheet 6 to the switch actuation point.
When turning the switch sheet 6 the switching signals are indicated
on the control panel (inlet r1).
– Tighten screw 7.
– Switch the machine off and on again.
– Let the machine move to its initial position and check the position
of the fabric support plate.

Correction of the distance between reference switch and switch

sheet
– Loosen the nuts 8.
– Screw the reference switch 5 out or in so that the distance between
reference switch 5 and switch sheet 6 does not exceed 0.5 mm.
– Tighten the nuts 8.

14

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 7. Longitudinal motion of the fabric support plate

3 2 1 1

Caution: Danger of injury!

Exercise utmost caution when making adjustments with the machine
running.
3
Note
Please observe the necessary program setting as described in
chapter 1.1.

Standard checking
When the machine is in reference position, the distance between the
edge 3 of the fabric support plate 2 and the front edge 1 of the throat
plate support should amount to approx. 113 mm.
The distance between reference switch and switch sheet must not
exceed 0.5 mm.
– Switch the machine on.
– Press the keys “P” and “ß” on the control panel simultaneously.
– Enter code “2548”.
– Press key ”OK”.
The control switches to the technician level.
– Select the menu “608” with the key “+”.
1 – Switch on the menu with key ”OK”.
The machine runs to its initial position.
– Switch the machine off.
– Check the distance between the edge 3 of the fabric support plate
and the front edge 1 of the throat plate support.

15

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 5 4 6

Correction
– Switch the machine on and press the keys “P” and “ß” on the
control panel simultaneously.
– Enter code “2548”.
– Press key ”OK”.
The control switches to the technician level.
– Select the menu “603”with the key “+”.
In this mode the step motors are dead.
– Switch the menu on with key ”OK”.

Caution: Danger of injury!

Exercise utmost caution when making adjustments with the machine
running.

– Shift the fabric support plate manually to the desired measurement.

– Loosen the screws 5.
– Set the switch sheet 4 to the switch actuation point.
When shifting the switch sheet 4 the switching signals are
indicated on the control panel (inlet r2).
– Tighten the screws 5.
– Switch the machine off and on again.
– Let the machine move to its initial position and check the
measurement.

Correction of the distance between reference switch and switch

sheet
– Loosen the nut.
– Screw the reference switch 6 out or in so that the distance between
reference switch 6 and switch sheet 4 does not exceed 0.5 mm.
– Tighten the nut.

16

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 8. Clamping plates
8.1 Inserted clamping plates

ô= 0
4 3 2 1

Caution: Danger of injury!

Switch the main switch off. 3
Adjust the clamping plates only with the machine switched off.

Standard checking
The inserted clamping plates 1 and 2 should be in the holding
groove 4 of the fabric support plate in parallel position and without
clearance.
Inserting and removing must, however, be fingertip easy.
– Insert both clamping plates and check whether there is as little
clearance as possible.
– Remove the clamping plates and check whether this is easily
possible.

Correction
– Adjust the screws 3 correspondingly.

17

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 8.2 Aligning the clamping plates

X2

X1

3 2 1 4

Caution: Danger of injury!

Switch the main switch off.
Adjust the clamping plates only with the machine switched off.

Standard checking
Both clamping plates 3 must be adjusted in such a way that the
distance between clamping plate and fabric support plate 1 is equal
everywhere (distance X1 = distance X2).
– Put on the right clamping plate.
– Check distance X1 and X2.

Correction
– Insert the right clamping plate.
– Loosen the screw 4 with a hexagonal spanner.
– Turn the eccentric 2 correspondingly.
– Tighten screw 4.
– Insert and adjust the left clamping plate.

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 8.3 Adjusting the spreading

2 X 1 4

Caution: Danger of injury!

Exercise utmost caution when making adjustments with the
machine running.
3
Standard checking
The distance X between the clamping plates 2 and the fabric support
plate 1 should amount to 1.3 mm (non-spreaded) and to 0.3 mm
(spreaded).
– Insert the clamping plates 2 and switch the machine on.
– Press the keys “P” and “F” on the control panel simultaneously.
– Enter code “2548”.
– Press key ”OK”.
The control switches to the technician level.
– Select the menu “601” with the key “+”.
– Switch the menu on with key ”OK”.
– Select the function “Y03” (closing the fabric clamp).
– Press key ”OK”.
The fabric clamps close.
– Check whether the distance X amounts to 1.3 mm.
– Select the function “Y04”.
– Press key ”OK”.
The fabric clamps spread.
– Check whether the distance X amounts to 0.3 mm.

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 X 6 5 8 7

Correction clamping plate

– Switch the machine on.
– Press the keys “P” and “F” on the control panel simultaneously.
– Enter code “2548”.
– Press key ”OK”.
The control switches to the technician level.
– Select the menu “601” with the key “+”.
– Switch the menu on with key ”OK”.
– Select the function “Y03” (closing the fabric clamp).
– Press the key ”OK”.
The fabric clamps close.
– Loosen the screws 6.
– Set the distance X to 1.3 mm (basic adjustment) with the hexagonal
spanner 5.
– Tighten the screws 6.
– Select the function “Y04”.
– Press key ”OK”.
The fabric clamps spread.
– Loosen screw 7.
– Set the distance X to 0.3 mm with the hexagonal spanner 8.
– Tighten screw 7.

– Adjust the left clamping plate as well.

Note!
The desired spreading must only be set with the screws 6 according to
the sewing material used.

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 8.4 Height of the fabric clamps

3 2 Ø 12 mm 3 2 1

Caution: Danger of injury!

Switch the main switch off.
Adjust the fabric clamp height only with the machine switched off.
3

Standard checking
The distance between the open fabric clamps 2 and 3 should amount
to 12 mm.
– Remove the clamping plates.
– Open the clamping plate and test e.g. with a twist drill Ø 12 mm
whether the fabric clamps 2 and 3 have the required distance.

Correction
– Adjust the distance with core pin 1.

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 8.5 Adjusting the locking sheet

2 1 3

Caution: Danger of injury!

Switch the main switch off.
Adjust the locking sheets only with the machine switched off.

Standard checking
The locking sheets 1 must be adjusted in such a way that the stops 3
of the clamping plates abut centrally and as tight as possible.
– Insert the clamping plates.
– Check the position of the locking sheet 1 to the stop 3.

Correction
– Adjust the locking sheet 1 with the special spanner 2 (in the
accessories).

3 1

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 8.6 Arrest of the clamping plates

2 1 4 3

Caution: Danger of injury!

Exercise utmost caution when making adjustments with the machine
running.
3
Standard checking
There must be a minimum clearance in the height of the inserted
clamping plates 2 when:

· no material is loaded

· approx. 8 mm thick material is loaded and the clamps are closed.

– Insert the clamping plates.
– Switch the machine on.
– Close the fabric clamps.
– Check at the fabric clamp fixture 1 whether the clamping plate can
be minimally lifted.
– Load 8 mm thick material.
– Check at the fabric clamp fixture 1 whether the clamping plate can
be minimally lifted.

Correction
– Switch the machine off.
– Remove the clamping plates.
– Loosen the core pin 3.
– Adjust the stop 4.
– Tighten screws 3.

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 8.7 Adjusting the fabric clamping pressure

2 1 2 4 3

Caution: Danger of injury!

Switch the main switch off.
Adjust the fabric clamping pressure only with the machine switched off.

Standard checking
The clamping pressure should be adjusted in such a way that the
sewing material is clamped safely and tightly.
Please observe that the sewing material is not damaged by a too high
pressure.
The standard pressure amounts to 4 bar.

Correction
– Switch the machine off and tilt it up.
– Loosen the counter-nut 3 at the regulator 2 so that the scale 4 is
visible.
– Set the pressure with the hexagonal spanner 1.
– Tighten the counter-nut 3.
– Check the clamping of the material.

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 9. Adjusting the seam width
9.1 Presetting the seam width

B 2 A 1 B A 3

Caution: Danger of injury!

Switch the main switch off.
Adjust the seam width only with the machine switched off. 3

Standard
You can choose among two seam widths:

· Seam width “Narrow” = Lever 2 mounted in position B

· Seam width “Wide” = Lever 2 mounted in position A

The seam width “Narrow” is 2.2 mm and “Wide” 3.3 mm.

Attention: Danger of breakage!

The mechanical components of each sewing equipment are to be

used only with one seam width, and so cannot be changed or
adjusted either in the sewing equipment configuration.
When the sewing equipment is changed, the sewing width will
automatically match the sewing equipment.
Both sewing width - electronical and mechanical must be either both
“narrow” or both “wide”.
Under the menu «502» it is possible to check the value of the
electronical seam width for the sewing equipment.
When changing the configuration of the sewing equipment and
the sewing width, please make sure to have the corresponding
components of the sewing equipment mounted.

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 Setting the sewing equipment
– Press the keys “P” and “F” of the control panel simultaneously.
– Enter code “2548”.
– Press the “OK” key.
The control switches to the technician level.
– Select the menu “500" (configuration automatic buttonholer).
– Press the “OK” key.
– Select the menu “511"
– Press the “OK” key.
– Set the sewing equipment (the seam width will then be adjusted
automatically to match the sewing equipment - see table).

Class Sewing equipment

narrow wide
559 - 151 E1501 E1521
E1502 E1522
E1504 E1524
E1551 E1571
E1553 E1573
E1590 E1595

Correction
– Unscrew the side cover at the arm 1.
– Screw out screw 3.
– Screw the screw in drill-hole A or B according to the desired seam
width.
– Switch the machine on.

B 2 A 1 B A 3

Attention: Danger of breakage!

After altering the seam width, correct the looping stroke in any case.

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 Notes:

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 9.2 Needle zero position

2 1 4 3

Caution: Danger of injury!

Switch the main switch off.
Set the needle zero position only with the machine switched off.

Standard checking
The needle bar oscillates unidirectionally from the left (inside) to the
right (outside).
The needle zero position is on the left (inside).
With the needle zero position the inner stitches of the forward and
backward lip must be in a line.
Note
Please observe the necessary program setting as described in
chapter 1.1.
– Set the wide seam width. (See chapter 9.1)
– Insert a short needle.
Part Number 0558 006066.
– Adjust the fabric clamps right to the outside. (See chapter 20)
– Load a piece of cardboard as sewing material.
– Sew a buttonhole without cutting it open.
– In case of a wide throw the inner stitches of the lip must lie exactly
one on top of the other.

Correction
– Unscrew the head and side covers.
– Loosen screws 1 and 2 with the hexagonal spanner 4.
– Shift the yoke 3 up or down.
– Tighten screws 1 and 2.
– Sew a new buttonhole and check the stitches.

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 10. Cutting knife (Eyelet knife)
10.1 Position of the cutting knife

Caution: Danger of injury !

Switch the main switch off.
Adjust the cutting knife only with the machine switched off.
3
Standard checking
In case of automates for “cutting after sewing” the cutting knife 2
should cut exactly between the seam rows and in the center of the
eyelet (see illustration a).
In case of “cutting before sewing” the cutting knife should cut exactly
on the superimposed stitches and around the eyelet (see illustration b).

Attention: Danger of breakage !

Please take absolute care that the cutting knife corresponds to the
subclass and to the sewing equipment.

According to the sewing equipment the position of cutting knife 2 and

cutting block 1 (not in use on the photo) can be different.
Please take care in any case that the correct position of cutting knife
and cutting block is adjusted when the sewing equipment is changed
on the control panel.
The position of the cutting knife is indicated in the table on the next
page.
Furthermore, the matching clamping plates and fabric clamps must be
used for the new sewing equipment.
The machine must not be operated before the cutting block, the cutting
knife, the clamping plate and the fabric clamps have been adapted to
the new sewing equipment.

a) b)

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 The cutting knife has to be adjusted in such a way that it cuts in the
center of the sewn buttonhole shape.
– Insert the cutting block.
– Insert a short needle.
– Load a piece of paper or cardboard as sewing material.
– Sew a buttonhole.
– Check the position of the cut.

Correction
– Loosen two screws 5 at the base plate 3.
– Correct the position of the cutting knife 2 laterally.
– Tighten the screws 5 at the base plate 3.
– Loosen screw 4.
– Shift the cutting knife 2 to the front or to the back.
As a presetting shift the cutting knife to the setting dimension X
(center of buttonhole eyelet to the groove of the throat plate holder)
listed in the table below.
As a fine adjustment shift the cutting knife in such a way that it cuts
in the center of the buttonhole shape.
– Tighten screw 4.
– Loosen screw 6.
– Position guide 7 close to the cutting knife.
– Tighten screw 6.

5 4 3 2 7 6

Sewing equipment Setting dimension (X)

1501 / 1502
1521 / 1504 approx. 59 mm
1524 1522

1573 1551 1553 approx. 47 mm

1590 / 1595 approx. 49,5 mm up to

center of the eyelet

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 10.2 Adjusting the knife parallel to the cutting block

3 2 1 7 6 5 4

– Loosen screws 1, 2 and 3.

– Put the key 4 (in the accessories) on the hexagonal bolt 5 and
twist it.
– Push the cutting block 6 downward.
3

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 10.3 Cutting block adjustment

4 3 2 1 6 5

Caution: Danger of injury !

Switch the main switch off.
Adjust the cutting block only with the machine switched off.

The cutting length can be altered by changing the cutting block.

The cutting length is determined by the cutting block length.

Standard checking
The cutting block 3 must be in parallel position to the cutting knife 4.
The cutting block stop 5 has to be adjusted so that the knife mark on
the cutting block 3 reaches the indicated cutting length.

Correction
– Loosen screws 1.
– Adjust the cutting block 2 laterally to the cutting knife 4.
– Tighten screws 1.
– Loosen screw 2.
– Adjust the cutting block 3 in longitudinal direction to the cutting
knife 4.
– Tighten screw 2.
– Loosen screw 6.
– Position the stop 5 close to the cutting block.
– Tighten screw 6.

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 10.4 Adjusting the switch for the trimming system

1 2 1

Caution: Danger of injury !

Switch the main switch off.
Adjust the trimming system only with the machine switched off.
3
Standard checking
Before the fabric support plate continues transporting the fabric, the
cutting stamp must be in its upper position.
In order to avoid a possible collision, switch 1 checks the position of
the cutting stamp.

Correcting the height of the switch

– Loosen screw 2.
– Adjust the height of switch 1 accordingly.
– Tighten screw 2.

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 10.5 Cutting pressure
Standard checking
The cutting pressure is adjustable in order to keep the strain of all
components as low as possible and to increase the durability of the
cutting knife.
According to the sewing material and the material thickness the cutting
pressure should be adjusted as low as possible. However, it has to be
adjusted in such a way that the material is safely cut.
The cutting pressure is coordinated to the different cutting lengths in
the program.

Correction
– See menu item 601.

10.6 Cutting duration

Standard checking
It is possible to set the cutting duration, to avoid an unnecessary long
cut on the material to be processed thus allowing a clean result.

Correction
– See chapter 24.6.4 see menu item 504

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 11. Looper height 2 3 4 1

8 7 6 5

Before adjusting the looping stroke as well as the needle bar height
and particularly after needle breakage it is necessary to check the
correct looper height.
Use gauge 2 for checking the looper height.

3
Caution: Danger of injury !
Switch the main switch off.
Adjust the height of the looper only with the machine switched off.

Standard checking
When the gauge is put on the looper turrets, please observe the
following:
– The drill-hole 1 of the gauge must be on top right.
– The tip of the left looper must be under the edge 3 of the gauge.
– The tip of the right looper must be under the edge 4 of the gauge.
– The looper points must just abut on the gauge.

– Remove the thread trimmer 9, the throat plate 10, the spreader
stops 5 and 8 as well as the spreaders 6 and 7 from the looper
turrets.
– Bring the needle bar in position “up” by turning the handwheel.
– Put the gauge 2 on the looper turret with the loopers inserted in the
looper turrets as far as it will go.
– In this position the rules mentioned above must be fulfilled.
10 9
Correction
– Adjust the correct looper height by slight alignment of the loopers.

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 12. Adjusting the looping stroke

2 1 4 3

Caution: Danger of injury !

Switch the main switch off.
Adjust the looping stroke only with the machine switched off.

Standard checking
The looping stroke is the way of the needle bar from its lowest position
up to the point where the left or right looper tip is at the level of the
middle of the needle.
The looping stroke is 2.7 mm.
– Turn the handwheel in rotation direction until the needle is in the
bottom dead center.
– Measure the distance between the edge 1 and the top edge of
needle bar 2 with a slide gauge.
– Scale down the measurement on the slide gauge by 2.7 mm.
– Put the slide gauge with the scaled-down measurement on the
edge 1.
– Slowly continue turning the handwheel in rotation direction until the
needle bar hits the slide gauge.
The needle bar is in looping stroke position.
– Check whether the looper point is at the level of the middle of the
needle (see illustration on the left).
– Repeat the same procedure with the second looper.

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 6 4 3 5

Correction
Shift the clamping rings 3 and 4 in such a way that both looper points
have the same distance to the needle.
Adjust the left looper 8 and the right looper 7 so that both looper points
in looping stroke position have the same position (X) to the needle.
That means both looper points must be at an equal distance either
before or behind the needle.
– Loosen the screws at the clamping rings 3 and 4. 3
Adjust the looper position as described by shifting the clamping
rings.
– Tighten the screws 3 and 4.
It must still be possible to turn the looper turret easily after
tightening the screws.
– If the looper points are not at the level of the middle of the needle,
loosen the screws at the eccentric 5.
– Turn the eccentric 5 until the looper points are at the level of the
middle of the needle.
– Tighten the screws at the eccentric 5.

Note
The disc 6 must still be freely movable after tightening.

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 13. Needle bar height

2 1 5 4 3

Caution: Danger of injury !

Switch the main switch off.
Adjust the needle bars only with the machine switched off.

Standard checking
The needle bar has to be adjusted in such a way that approx. ¾ of the
needle’s eye 6 is to be seen under the left looper point when the
needle bar has moved upward by 2.5 mm from the looping stroke
position.
– Turn the handwheel until the needle is in the bottom dead center.
– Measure the distance between the edge 1 and the top edge of
needle bar 2 with a slide gauge.
– Scale down the measurement on the slide gauge by the looping
stroke dimension +2.5 mm.
Example:
Looping stroke = 2.7 mm +2.5 mm = Scale the measurement down
by 5.2 mm
– Put the slide gauge with the scaled-down measurement on the
edge 1.
– Slowly continue turning the handwheel in rotation direction until the
needle bar hits the slide gauge.

Correction
– Loosen the screws at the adjusting rings 3 and 4.
– Adjust the height of needle bar 5.
– Tighten the screws at the adjusting rings 3 and 4.
Note
It must still be possible to turn the needle bar easily after tightening the
screws.

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 14. Distance between looper and needle

4 1

Caution: Danger of injury !

Switch the main switch off.
Adjust the needle protection only with the machine switched off.

3
Standard checking
The looper points 1 and 4 should be in a distance of max. 0.1 mm to
the needle 3. The distance between looper and needle should be equal
during the whole rotary motion of the looper turret.
– Turn the handwheel until the left looper point is at the level of the
middle of the needle. Check the distance between needle and
looper point in the following positions.
1. Looper point basic position
2. Looper turret manually turned by 90°
3. Looper turret manually turned by 180°
If the distance between looper point and needle is different in the three
positions, first align the rotary centers of needle bar and looper turret.

Correction
– Loosen screw 2 at the corresponding looper.
– Set the distance between looper and needle accordingly.
– Tighten screws 2.

0,1 mm

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 15. Needle guard

Caution: Danger of injury !

Switch the main switch off.
Adjust the needle guard only with the machine switched off.

Standard checking
The needle 1 must slightly abut on the needle guard 2 until the looper
point have reached the needle.
The distance between looper and needle must amount to 0.1 mm. The
needle guard has been adjusted by the manufacturer. In general, a
readjustment is not required. If the needle size changes, it may be
necessary to re-adjust the needle guard correspondingly.

Correction
– Loosen the locknut.
– Twist the Allen screw 3 correspondingly.
– Tighten the locknut.

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 16. Spreader

6 5 4 3 2 1 8 7

Caution: Danger of injury !

Switch the main switch off.
Adjust the spreader only with the machine switched off.

Standard checking 3
The distance between the fork spreader 5 and the left looper 4 must
correspond to the thickness of the looper thread used (see illustration
X opposite).
The right spreader 2 should move as closely as possible on the top
side of the right looper 3, but without touching it.
The spreaders being under spring pressure are held in their end
position by the stops 1 and 6.
The fork of the left spreader 5 should be exactly above the thread hole
of the left looper 4 (see illustration opposite) and the point of the right
spreader 2 centrally above the tip of the right looper 3 (see illustration
at the bottom of the page).

Correction
– For adjusting the distance between spreader and looper slightly
align the spreaders.
– For setting the final positions of the spreaders loosen the screws 7
or 8 at the looper to be adjusted.
– Turn spreader stop 1 or 6 slightly.
– Tighten screw 7 or 8.

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 17. Spreader plate

X1 X2

3 2 1

Caution: Danger of injury !

Switch the main switch off.
Adjust the spreader plate only with the machine switched off.

Standard checking
The opening and closing of the spreaders is effected by the alternate
motion of the spreader plate 2.
When the needle bar is in the bottom dead center for the right stitch,
the distance between spreader plate 2 and spreader shank 1 must be
exactly the same as that between spreader plate 2 and spreader shank
3 (dimension X1 = dimension X2), when the needle is in the bottom
dead center for the left stitch.

Correction
– Loosen the screws at the clamping rings 4 and 6.
– Turn the clamping rings in such a way that there is an equal
distance of the spreader plates to the spreader shanks.
– Tighten the screws at the clamping rings 4 and 6.
Note
The disc 5 must still be freely movable after tightening.

6 5 4

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 18. Throat plate

Caution: Danger of injury !

Switch the main switch off.
Adjust the throat plate only with the machine switched off.

3
Standard checking
The needle should penetrate the needle hole of the throat plate on one
side at the edge 1.
The throat plate has to be positioned as highly as possible.
Thus it is avoided that the material is pressed down too much at the
moment of the needle penetration.
During the sewing process there must be a small distance to the throat
plate at the following points:

· Under the sewing material or the closed upper fabric clamps.

It must be possible for the sewing material to move over the throat
plate unhindered.

· Under the lower fabric clamps.

· Above the needle thread knife.

The needle thread knife must move as closely as possible under
the throat plate, but without touching it.

Correction
– Adjust the height of the throat plate at the stop screw 2 in the throat
plate guide.
By means of the stop screw the adjustment is maintained when
inserting the throat plate anew.

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 19. Adjusting the needle thread knife

3 2 1 4

Caution: Danger of injury !

Switch the main switch off.
Adjust the needle thread knife only with the machine switched off.

Standard checking
The cutting motion of the needle thread knife 2 is effected after sewing.
The exact cutting moment is fixed in the control.
When in final position the knife holder 3 must not touch the spreader
stop 1.
The needle thread knife should cut through the needle thread loop
taken up from the right looper at the looper front 5 only. If the needle
thread loop is cut through on both sides, this results in a too short
thread end and thus in skipped stitches at the seam beginning.
In the right final position the needle thread knife must neither be in the
thread zone nor touch the spreader stop.
There must be a distance of approx. 0.2 mm between needle and knife.
5 In cut-off position the knife must move approx. 1 mm beyond the
edge 4.
– Move the knife manually and check whether all rules mentioned
above are kept.

0,2 mm

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 8 7 6 5 12 11 10 9

Correction of the knife motion

– Loosen the counter-nuts 5 and 8.
– Adjust the stop screws 6 and 7 according to the rule.
– Tighten the counter-nuts 5 and 8.

Adjusting the height of the knife 3

– Loosen screw 10.
– Adjust the height of the knife holder 9 correspondingly.
Swing the knife holder 9 manually to check the free movement.
– Tighten screw 10 again.

Adjusting the distance to the needle

– Loosen screw 11.
– Shift knife 12.
– Tighten screw 11.

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 20. Adjusting the fabric clamps

2 1 6 5 4 7 3

Caution: Danger of injury !

Switch the main switch off.
Adjust the fabric clamps only with the machine switched off.

Standard checking
Between the needle 2 and the upper fabric clamp 1 there should be a
distance of 1 mm over the whole length and in the eyelet.
– Press key “P”.
– Select the menu “150”.
– Enter “+ 0.5”.
– Select the menu “162”.
– Set the cutting area to “0.7”.
– Insert the clamping plates.
– Insert a new needle.
– Check the distance between the upper fabric clamp 1 and the
3 needle 2.

Correction
– Loosen screws 3 (underside).
– Align the clamp bow 7 with fabric clamp 5 laterally to the needle.
– Tighten screws 3.
– Loosen screws 4.
– Align the clamp arm 6 with fabric clamp 5 in the eyelet as to the
needle.
– Tighten screw 5.

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 21. Thread controller spring

1 5 4 3 2

Caution: Danger of injury !

Switch the main switch off.
Adjust the thread controller spring only with the machine switched off.
3

Standard checking
The thread controller spring 1 must hold the looper thread tensioned
until the needle with the needle thread has accurately penetrated the
triangle formed by the spreader.
– Insert and clamp the material.
– Turn the machine manually and check whether the thread
controller spring tightens the looper thread firmly and long enough.

Correction of the spring travel

– Loosen screw 4.
– Adjust the stop disc 3.
Disc to the right = longer spring travel
Disc to the left = shorter spring travel
– Tighten screw 4.

Correction of the spring tension

– Loosen screw 5.
– Adjust the tension bolt 2.
Bolt to the right = higher tension
Bolt to the left = lower tension
– Tighten screw 5.

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 22. Maintenance

1 6 3 2

Caution: Danger of injury !

Switch the main switch off.
Maintenance work of the automatic buttonholer must only be carried
out with the machine switched off.

The daily or weekly maintenance work (cleaning and oiling) to be

carried out by the operators of the automatic buttonholer is described
in Part 1: Operating Instructions. This is only listed in the following
table to complete the picture.

Maintenance work to be carried out Operating hours

8 40 160 500

Automatic buttonholer
Remove the sewing dust from the area under the throat plate X
Check the oil level X
Check and clean the toothed belt X
Oil the cutting stamp 1 X
Oil the clamp arms 3 at the felt 2 X
Oil felt 6 at the cam X

Pneumatic system
Check the water level in the pressure regulator X
Clean the filter insert in the maintenance unit X
Make leak test of the system X

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 23. Annex
23.1 Adjusting operations without head cover

3 2 1

When the head cover is taken off, the machine is secured against
unintentional starting.
If you want to operate the machine without head cover for adjusting
purposes, the plug 2 can be put on the connecting cable 3. 3
The plug is in the switch casing 1.

Caution: Danger of injury !

Remove the head cover for adjustment work only.
Exercise utmost caution when making adjustments with
the machine running.

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 23.2 Fuses in the control box

The fuses 1 and 2 for the control are on the back of the control box.
Only insert the fuses indicated in the circuit diagram.

23.3 Exchange of the control

See:
Part 2: Installation Instructions.

· “Assembly of the main switch”

· “Assembly of the control”

· “Potential equalization”

· “Installing the sewing software”

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 24. Service menu (technician level)
In the service menu of the 559 various basic adjustments and test
programs can be executed.

24.1 Activating the service menu

– Press the keys “P” and “F” simultaneously on the control panel.
A code query appears.
– Enter the code “2548” with the cursor keys.
– Press key “OK”.
The menu item “500” (configuration of the automate) appears.

24.2 Selection of a menu item/submenu item

– Select the desired menu item with the keys “ñ” or “ò”.
Example: 550
– Press key “OK”.
The menu item is activated.

– Select the desired submenu item with the keys “ñ” or “ò”.
Example: 551
– Press key “OK”.
3
The submenu item is activated.

– Press key “ï”.

Switch back to the level before in the menu.

24.3 Multitest

The functions of the Multitest menu (input test etc.) can be reached as
described under 28.2.
However, some functions require that the motors are dead.
– Press the keys “P” and “ï” simultaneously on the control panel
and switch the main switch on.
– Select the desired submenu item with the keys “ñ” or “ò”.
Example: 601
– Press key “OK”.
The submenu item is activated.

24.4 Quitting the service menu

– Press key “ESC”.

The control switches back to the main menu.

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 24.5 List of menu and submenu items

Menu item Description

500 Configuration automatic buttonholer

501 Loading position
502 Throw width
503 Thread monitor
504 Duty cycle of the cutting block
511 Sewing equipment

520 Tension data for the needle thread calibration

521 Value 1
522 Value 2
523 Value 3
524 Value 4
525 Value 5
526 Value 6

550 Configuration operation

551 Push button
552 Brightness of sewing lamp
553 Brightness of the display
554 Keyboard signal

600 Multitest
601 Output test
602 Manual input test
603 Automatic input test
604 Sewing motor test
605 Step motor test
606 ROM or flash test
607 RAM test
608 Running to the reference position
609 Starting continuous operation
610 Checking the setting of the sewing instruments
611 Breakpoint
612 Cycle time to the loading position
613 Cycle time to “clamp open”

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 24.6 Menu items 500 (Configuration automatic buttonholer)

24.6.1 Menu item 501 (Loading position)

Via this menu item the desired loading position can be set.
Input: 0 … 68 (mm)
Standard: 68
The value entered corresponds to the distance from the cutting point.
The value “0” corresponds to the cutting-open position.
The standard value is identical with the seam beginning position.
– Quit the menu item with key “ESC”.

24.6.2 Menu item 502 (Throw width)

In this menu the throw width is adjusted between “wide” and “narrow”.

Attention: Danger of breakage !

The throw width must match the mechanical position of the throw
eccentric.
See chapter 2.3

Input: 1 = Narrow
2 = Wide
3
– Quit the menu item with the “ESC” key .

24.6.3 Menu item 503 (Thread monitor)

In this menu the needle thread monitor is set.

The set value means:
0 = Thread monitor off
1 … 10 = Number of stitches after which the sewing process
is aborted because of thread breakage
Input: 0 … 14
Standard: 7
– Quit the menu item with the “ESC” key .

24.6.4 Menu item 504 (Duty cycle of the cutting block)

The duration of the incision can be set individually so that the material
to be processed is cut open accurately and no longer than required.
Input: 200 … 600
Standard: 200
– Quit the menu item with the “ESC” key.

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 24.6.5 Menu item 511 (Sewing equipment)

Various sewing equipment can be used with the automatic buttonholer

559.
The selected sewing equipment is entered via this menu item.
Input: 1501, 1502, 1504, 1521, 1522, 1524, 1551, 1553 or
1573, 1590, 1595.

– Quit the menu item with key “ESC”.

24.7 Menu item 520 (Tension data for the needle thread calibration)

In this menu are set the characteristic values 1 to 6 for the solenoid of
the needle thread.

ATTENTION!
The characteristic values may only be altered when a new solenoid is
mounted.
The respective values are included with the delivery of a new solenoid.

24.8 Menu items 550 (Configuration operation)

24.8.1 Menu item 551 (Push button)

In this menu the function of the push button is converted.

1st adjustment = 1 (Standard)
– Key 1: The clamping plates are opened or closed.
– Key 2: The sewing process only starts with the clamping plates
closed.

2nd adjustment = 2
– Key 1: The clamping plates are opened or closed.
– Key 2: The sewing process starts.
The clamping plates are closed automatically.
– Quit the menu item with key “ESC”.

24.8.2 Menu item 552 (Brightness of the sewing lamp)

In this menu the brightness of the incorporated sewing lamp is set.

The set value means:
0 = Sewing lamp off
100 = Sewing lamp very bright

Standard: 100
– Quit the menu item with key “ESC”.

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 24.8.3 Menu item 553 (Brightness of the display)

In this menu the brightness of the display is set.

The set value means:
Input: 0…3
Standard: 2
– Quit the menu item with key “ESC”.

24.8.4 Menu item 554 (Keyboard signal)

In this menu the keyboard signal is switched on and off.

The set value means:
0 = Keyboard signal off
1 .. 50 = Keyboard signal in milli-seconds

Standard: 0
– Quit the menu item with key “ESC”.

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 24.9 Menu item 600 (Multitest)

24.9.1 Menu item 601 (output test)

Attention: Danger of breakage !

The switching of output elements can lead to collisions with other
machine elements as well as to damages to the automatic buttonholer.
Before switching on an output element make sure that this cannot
collide with other components.

Caution: Danger of injury !

Exercise utmost caution when making the output test with the machine
running.

In this menu the individual output elements can be switched.

– Select the desired output element with the keys “ñ” or “ò”.
The current status is shown in the display:
0 = output inactive
1 = output active
– Press key “OK”.
The output is converted.

Output Designation

Y01 Needle thread trimmer

Y02 Bobbin thread tension
Y03 Fabric clamp
Y04 Spreading
Y05 Needle thread puller
Y06 Cutter
Y07 Cutter
Y15 Cutter

– Quit the menu item with key “ESC”.

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 24.9.2 Menu item 602 (manual input test)

Caution: Danger of injury!

Exercise utmost caution when making the input test with the machine
running.

In this menu individual input elements can be tested.

– Select the desired input element with the keys “ñ” or “ò”.
The current status is indicated in the display:
0 = input inactive
1 = input active

Input Designation

S09 Push button 1

S10 Push button 2
S11 Foot pedal 1
S12 Foot pedal 2
S13 Foot pedal 3
R0 Sewing motor
R1 X-axis
R2 Y-axis
R3 Z-axis 3

– Quit the menu item with key “ESC”.

24.9.3 Menu item 603 (automatic input test)

Caution: Danger of injury !

Exercise utmost caution when making the input test with
the machine running.

With this menu item the function of all input elements is checked.
If the status of an input is altered, this input is automatically indicated
in the display.
– Quit the menu item with key “ESC”.

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 24.9.4 Menu item 604 (sewing motor test)

With this menu item the sewing motor can be checked.

During the test the speed can be increased in steps of 100.

Caution: Danger of breakage !

Before starting the sewing motor test remove the clamping plates in
any case.

Caution: Danger of injury !

Exercise utmost caution when making the sewing motor test.

– Increase the speed with the key “ñ”.

– Reduce the speed with the key “ò”.
– Quit the menu item with key “ESC”.

24.9.5 Menu item 605 (step motor test)

With this menu the step motors can be checked.

The step motors are checked with the related reference switches.

Attention: Danger of breakage!

Before starting the step motor test remove the clamping plates in any
case.

Caution: Danger of injury!

Exercise utmost caution when making the step motor test.

– Select the corresponding step motor A1...A3 with the

keys “ï” or “ð”.
– With the keys “ñ” or “ò” the step motor runs each 20 steps
forwards or backwards.
On the right of the display the steps done from the start position
are indicated. The switching status of the pertaining reference
switch appears in the center.

A 2 1/0 Steps

A1 = X-direction (transversal motion of the fabric support plate)

A2 = Y-direction (longitudinal motion of the fabric support plate)
A3 = Z-direction (rotary motion of the sewing works)

– Quit the menu item with key “ESC”.

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 24.9.6 Menu item 606 (ROM or flash test)

In this menu item the read-only memory (ROM) and the flash memory
are checked.
Display:
on the left: Calculated checksum
on the right: 1 = Memory OK
0 = Memory not OK
– Quit the menu item with key “ESC”.

24.9.7 Menu item 607 (RAM-Test)

In this menu item the working memory (RAM) is checked.

r1 or r2 = 1 = Working memory works faultlessly
r1 or r2 = 0 = Error in the working memory
– Quit the menu item with key “ESC”.

24.9.8 Menu item 608 (Moving to the reference position)

In this menu the it is possible to start a reference run.

This testing program is particularly helpful for the setting of the sewing
machine. 3

Caution: Danger of injury !

Exercise utmost caution when setting the machine.

24.9.9 Menu item 609 (Starting continuous operation)

In this menu item it is possible to start a continuous operation.

Before the sewing starts, a safety check with the message INFO 609
will appear first. It can be confirmed by pressing the “OK” key or be
cancelled by pressing the “ESC” key.

Caution: Danger of injury !

Exercise utmost caution when running the machine on continuous
operation.

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 24.9.10 Menu item 610 (Checking the setting of the sewing instruments)

In this menu item the settings of the sewing instruments can be

checked.
In order to do so, the sewing motor drives to the staking-out position
UDC (Upper Dead Center) for calibration and then to the different
positions for the checking of the looping stroke, needle stroke, needle
guard and spreader position

Caution: Danger of injury !

Exercise utmost caution when setting the machine.

– Select the menu item 610 by using the key “ñ” or “ò” .
– Press the “OK” key.
The machine references.
The display reads

610 00

– Insert the locking peg 1 and check whether the peg engages in the
groove of the arm shaft.
In this position the needle bar should be positioned in the upper
dead center.
– Press the “OK” key.
The display reads:

610 01

– Remove the locking peg 1.

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 – Press the “OK” key.
The sewing motor drives to testing position 2 (left looping stroke).
The display reads:

610 02

– Check, whether the tip of the left looper 2 points to the middle of
the needle.

If the looper’s position needs adjustment, proceed as follows:

3
– Press the “F” key.
The machine drives back to position “0".
The display reads:

610 99

– Lift up the sewing machine.

The screws for the looper setting are now accessible.

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 – Adjust the looper’s position.
– Put the sewing machine down.
– Press the “OK” key.
The sewing motor drives back to testing position 2.
– Check the looper’s position.

– Press the “OK” key.

The sewing motor drives to testing position 3 (right looping stroke).
The display reads:

610 02

– Check the looper’s position and, if needed, adjust according to the

above mentioned description.

With each further pressing the “OK” key, the next sewing instrument’s
testing position appears.
– Select the positions one after the other and check their settings.

Position Setting
1 Setting the locking positions (see chapter 2)
2 Left looper to the needle’s middle (see chapter 12)
3 Right looping stroke (see chapter 12)
4 Needle bar height (see chapter 13)

ATTENTION!
Contrary to chapter 13, with this setting a position is selected, so that
the complete needle’s eye is to be seen under the left looper tip.

5 Left needle guard (see chapter 15)

6 Right needle guard (see chapter 15)
7 Left spreader opened (see chapter 16)
8 Left spreader closed (see chapter 16)
9 Right spreader opened (see chapter 16)
10 Right spreader closed (see chapter 16)

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 24.9.9 Menu item 611 (Breakpoint)

With the aid of the testing program, the switching order of the valves
can be checked.
This testing program is particularly helpful for the setting of the thread
catcher and the thread trimming systems because one can see
precisely how the individual components lie in regard to the needle
thread, looper thread and the gimp.

Caution: Risk of injury !

The testing program serves only for the checking of cycles and
functions. Maintenance and setting work should not be conducted
when running the testing program.

The following is the meaning values set:

0= normal sewing cycle, the testing program is turned off.
1= the sewing cycle is stopped after switching the valves of the
thread catcher on.
2= the sewing cycle is stopped after switching the valve of the
respective thread trimming system on.
3= the sewing cycle is stopped after switching each valve on.

– Select the desired item with the keys “ñ” or “ò”.

– Press the “OK” key.
The breakpoint mode will be turned on.
– Press the “ESC” key.
The control unit switches back to the main menu. 3
– Start the testing program through the control panel, hand switches,
or the foot pedal.
– The machine moves to the first breakpoint and stops.
– The control panel will display an Info-No.
The information is intended for the DA Service.
– Press the “OK” key two times.
– The machine moves to the next breakpoint.
– You can exit the breakpoint mode by switching off the main switch.

24.8.10 Menu item 612 (cycle time)

In this menu item the “cycle time from the sewing start back to the
loading position” can be ascertained.
– Quit the menu item with key “ESC”.

24.8.11 Menu item 613 (cycle time)

In this menu item the “cycle time from the sewing start to “clamp
open”” can be ascertained.
– Quit the menu item with key “ESC”.

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 25. Error messages
Error Info/Description Remedy

Sewing motor timeout · Replace the cable

1051 · Cable to the sewing motor
reference switch faulty
· Reference switch defective · Replace the reference switch

1052 Sewing motor excess current

· Cable of sewing motor faulty · Replace the sewing motor cable
· Sewing motor defective · Replace the sewing motor
· Control defective · Replace the control

1053 Too high mains voltage Check mains voltage

1055 Sewing motor overcharge

· Sewing motor blocked/moves · Eliminate the blocking/rough
too heavy running
· Sewing motor defective · Replace the sewing motor
· Control defective · Replace the control

1056 Sewing motor excess

temperature · Eliminate the rough running
· Sewing motor moves too · Replace the sewing motor
heavy · Replace the control
· Sewing motor defective
· Control defective

1058 Sewing motor speed · Replace the sewing motor

Sewing motor defective

1062 Sewing motor IDMA Switch the machine off and on again
Autoincrement
Malfunction

1302 Sewing motor: current supply · Eliminate the blocking

fault · Check /
Encoder cable not connected / Replace the encoder cable
defective · Replace the sewing motor
Encoder defective

1342 Sewing motor fault · Switch the machine off and on

- Internal fault again
1344 · Software update
· Inform DA-Service

2101 Step motor X-axis timeout

reference
· Cable to the reference switch · Replace the cable
faulty
· Reference switch defective · Replace the reference switch

2152 Step motor X-axis excess · Replace step motor X-axis

current · Replace the control

2153 Step motor X-axis excess Check the mains voltage

voltage
Too high mains voltage

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 Error Info/Description Remedy

2155 · Step motor X-axis · Eliminate the blocking/rough

overcharge running
· Step motor X-axis · Replace step motor X-axis
blocked/moves too heavy · Replace the control
· Step motor X-axis
defective
· Control defective

2156 · Step motor X-axis · Eliminate rough running

excess temperature · Replace step motor X-axis
· Step motor X-axis · Replace the control
moves too heavy
· Step motor X-axis
defective
· Control defective

2162 · Step motor X-axis · Switch the machine off and on

IDMA Autoincrement again
· Malfunction

2201 · Step motor Y-axis · Replace the cable

timeout reference · Replace the reference switch
· Cable to the reference switch
faulty
· Reference switch defective

2202 · Step motor Y-axis · Eliminate the blocking

Current supply fault · Check / 3
· Step motor Y-axis Replace the encoder cable
blocked · Replace step motor Y-axis
· Encoder cable not
connected/defective
· Encoder defective

2252 · Step motor Y-axis · Replace step motor Y-axis

excess current · Replace the control
· Step motor Y-axis defective
· Control defective

2253 · Step motor Y-axis · Check the mains voltage

excess voltage
· Too high mains voltage

2255 · Step motor Y-axis · Eliminate the blocking/rough

overcharge running
· Step motor Y-axis · Replace step motor Y-axis
blocked/moves too heavy · Replace the control
· Step motor Y-axis defective
· Control defective

2256 · Step motor Y-axis · Eliminate the blocking/rough

excess temperature running
· Step motor Y-axis · Replace step motor Y-axis
blocked/moves too heavy · Replace the control
· Step motor Y-axis defective
Control defective

2262 · Step motor Y-axis · Switch the machine off

IDMA Autoincrement and on again
·Malfunction

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 Error Info/Description Remedy

2301 · Step motor Z-axis · Replace the cable

timeout reference · Replace the reference switch
· Cable to the reference switch
faulty
·Reference switch defective

2302 · Step motor Z-axis · Eliminate the blocking

Current supply fault · Check/Replace the encoder cable
· Step motor Z-axis · Replace step motor Z-axis
blocked
· Encoder cable not
connected/defective
· Encoder defective

2352 · Step motor Z-axis · Replace step motor Z-axis

excess current · Replace the control
· Step motor Z-axis defective
· Control defective

2353 · Step motor Z-axis · Check the mains voltage

excess voltage
· Too high mains voltage

2355 · Step motor Z-axis · Eliminate the blocking/rough

overcharge running
· Step motor Z-axis · Replace step motor Z-axis
blocked/moves too heavy · Replace the control
· Step motor Z-axis defective
· Control defective

2356 · Step motor Z-axis · Eliminate the rough running

excess temperature · Replace step motor Z-axis
· Step motor Z-axis · Replace the control
moves too heavy
· Step motor Z-axis defective
· Control defective

2362 · Step motor Z-axis · Switch the machine off

IDMA Autoincrement and on again
· Malfunction

2911 · Step motor fault · Switch the machine off and on

- · Internal fault again.
2914 · Software update
· Inform DA-Service

3100 · Machine voltage fault · Check the mains voltage and

- · Short-term mains voltage dip stabilize, if necessary
3103

3107 · Machine temperature · Check the ventilation openings

· Ventilation openings · Clean the ventilation grids
closed · Let the machine cool down
· Ventilation grids soiled
· Too high ambient temperature

3221 · Machine thread tension · Switch the machine off and on

- regulator again
3222 · Internal fault · Software update
· Inform DA-Service

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 Error Info/Description Remedy

3300 · Fault in the machine control · Switch the machine off and on
- · Internal fault again
3724 · Software update
· Inform DA-Service

4460 · Operation BF-4 · Switch the machine off and on

- · Malfunction again
4468 · Inform DA-Service

4500 · Menu system fault · Switch the machine off and on

- · Internal fault again
4503 · Software update
· Inform DA-Service

6000 · Driver fault · Switch the machine off and on

- · Internal fault again
6299 · Software update
· Inform DA-Service

6351 · I²C fault · Replace the control

- · Control defective
6354

6400 · Driver fault · Switch the machine off and on

- · Internal fault again
6999 · Software update
· Inform DA-Service 3
7451 · Communication · Switch the machine off
7453 test interface and on again
7454 · Internal fault

7452 · Communication · Eliminate the cause of the fault

7455 test interface · Replace the cable
· Line fault · Switch the machine off
· Cable test interface and on again
defective
· Internal fault

7551 · Communication · Switch the machine off and on

- control panel interface again
7555 · Internal fault · Software update
7558 · Inform DA-Service
7559

7556 · Communication · Eliminate the cause of the fault

7557 control panel interface · Replace the cable
· Line fault
· Cable control panel interface
defective

8151 · IDMA fault · Switch the machine off and on

8156 · Malfunction again
- · Control defective · Replace the control
8159
8152 · IDMA fault · Switch the machine off and on
- · Internal fault again
8154 · Software update
· Inform DA-Service

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 Error Info/Description Remedy

8251 · ADSP Boot / · Switch the machine off and on

8255 Boot failure again
· Internal fault · Software update
· Inform DA-Service

8252 · Boot failure · Switch the machine off and on

- · Malfunction again
8254
8256
-
8258

8351 · Infrastructure fault · Switch the machine off and on

8801 · Internal fault again
- · Software update
8805 · Inform DA-Service
8806
8890
8891

9000 · Seam description fault · Switch the machine off and on

- · Internal fault again
9099 · Software update
· Inform DA-Service

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 26. Troubleshooting
Caution: Danger of injury!
Exercise utmost caution when eliminating defects with the machine
switched on.

Description of fault Possible cause Error elimination

The display shows a message

indicating the possible cause.

The automate does not start up. Display: Info 200 Turn the handwheel in the direction
Before sewing start the needle of rotation so that the needle is in
is in front of the wrong stitch or front of the left stitch.
not in the position “up”
respectively.
Correct position:
The needle is in front of the left
stitch.

Display: Info 210 - Check the air pressure at the

Too low air pressure for the manometer
pneumatic components. - Has the compressed air hose been
connected?
- Check compressed air fluctuations
- Check all compressed air hoses
and connections 3
Display: Info 220 Activate the threading mode and
Thread breakage thread the sewing thread anew.

Display: Info 500 Deactivate the threading mode

Threading mode is active.

Display: Err 501 Deactivate the threading mode.

Display: Err 502. Put on head cover or bridge

Skipped stitches The needle is blunt, bent or Insert a new needle

incorrectly inserted in the Insert the needle in the needle bar
needle bar. correctly.

Needle and looper thread are Check threading of needle and

threaded incorrectly. looper thread
(See Operating Instructions)

The thread reel holder is Check the thread reel holder

mounted wrongly. (See Assembly Instructions)

Too tight thread tension. Check the thread tension

(See Operating Instructions)

The fabric is incorrectly held. Check the fabric clamping pressure

(see chapter “Fabric clamping
pressure”).

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 Description of fault Possible cause Error elimination

Skipped stitches The material is not spread or Check the spreading

spread too little. (see chapter “Spreading”).

The matching needle size has Change the needle size.

to be chosen according to the (See Operating Instructions)
material, the material thickness Attention!
and the thread used. After changing the needle size the
distance needle-looper has to be
checked.

Throat plate, loopers or Have the parts reworked by the

spreaders have possibly been service personnel.
damaged by the needle.

Possibly parts have been Check the sewing equipment parts

inserted which do not match the according to the equipment sheet.
sewing equipment, as e.g.
throat plate, looper, spreader,
clamping plates, upper/lower
fabric clamps.

When converting the seam Adjust the looping stroke

width the looping stroke has not (see chapter “Looping stroke”).
been readjusted.

Looper or spreader are Check the adjustments described in

adjusted wrongly. the following chapters of the Service
Even if no wrong adjustment is Instructions:
to be seen and the “Adjusting the locking positions”
above-mentioned measures did “Adjusting the looping stroke”
not lead to an improvement, “Needle bar height”
check the opposite points once “Distance between looper and
again. needle”
“Needle protection”
“Spreader”
“Spreader plate”
“Throat plate”
“Rotary thread take-up disc”

Thread breakage Needle and looper thread are Check threading of needle and looper
threaded incorrectly. thread (see Operating Instructions
“Thread the needle thread”/ “Thread
the looper thread”).

The needle is bent, Insert a new needle. Insert the

sharp-edged or incorrectly needle in the needle bar correctly.
inserted in the needle bar.

The thread used is knotty, hard Use recommended threads only

or too thick and thus unsuitable. (see Operating Instructions:
Needles, threads and gimps).

The thread tensions are too Check the thread tensions

tight for the thread used. (see Operating Instructions “Thread
tensions”)

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 Description of fault Possible cause Error elimination

Thread breakage Thread-guiding parts as e.g. Check whether thread-guiding parts

thread pipes, thread guides or are sharp-edged.
the rotary thread take-up disc
have sharp edges.
Check whether the throat plate, Have the parts reworked by the
the loopers or the spreaders service personnel.
have been damaged by the
needle.

Loose stitches The thread tensions are not Check the thread tensions
adapted to the material, the (see Operating Instructions “Thread
material thickness or the tensions”).
threads used.

Needle and looper thread are Check the threading of needle and
threaded incorrectly. looper thread (see Operating
Instructions “Thread the needle
thread”, “Thread the looper
thread”).

The buttonhole is cut open The set cutting pressure is too Increase the cutting pressure (see
inaccurately low. chapter “Cutting pressure”)

Too short duty cycle of the Increase the duty cycle

cutting stamp (See menu item 504)

3
The knife edge is blunt or Insert a new knife
chipped. (see chapter “Cutting knife / Eyelet
knife”).

The knife works on a Rework the cutting block or insert a

non-matching cutting block. new one.
No matter whether buttonholes (see chapter “Adapting the cutting
are cut open before or after blocks”).
sewing or buttonholes with or
without eyelet are sewn, always
insert the matching cutting
block.
Cutting blocks with two knife
marks lead to an inaccurate
cut.

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 Description of fault Possible cause Error elimination

Needle breakage The needle size is unsuitable Change the needle size.
for the material or the thread.

The needle hits the fabric Check the subclass on the control
clamps panel.

When changing the seam width Set the upper fabric clamps apart as
the upper fabric clamps have far as required.
not been set apart or not wide
enough.

When changing the seam width Insert lower fabric clamps matching
the lower fabric clamps have the sewing equipment.
not been exchanged.

No reliable seam beginning The remaining tension is too Readjust the remaining tension
or unthreading respectively tight for the needle thread so (see Operating Instructions “Thread
that the thread at the seam tension”).
beginning is too short for the
next sewing start.

Faulty feed of the fabric The fabric support plates Check the motion of the fabric
support plate collides with other components. support plate at low speed to find
possible collisions.

The fabric support plate is only Check all components belonging to

heavily movable when the the drive of the fabric support plate.
machine is switched off.

Faulty rotation of the sewing The toothed belts are Retighten toothed belts or replace
works insufficiently tightened. them, if necessary.

Toothed belts and toothed lock Clean the toothed belts and toothed
washers are soiled. lock washers. Replace the toothed
belts, if necessary.

The sewing works collides with Check the motion of the sewing
other components. works rotation at low speed to find
possible collisions.

The sewing works is only Check the adjusting rings at the

heavily rotatable when the looper support drive and at the
machine is switched off. needle bar drive and set a slight
The adjustable rings at the clearance, if required (see chapter
looper support drive or at the “Adjusting the looping stroke”,
needle bar drive are pressed “Needle bar height”, “Spreader
too tight against the driving plate”).
levers or the yoke.

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 Description of fault Possible cause Error elimination

Faulty rotation of the sewing Possible rough running of Check all components belonging to
works individual components the sewing works rotation.
If neither faulty components nor
rough running are found, the
problem can in some cases be
solved by altering the following
parameters:
- Speed reduction
- Increase of the stitches in the
eyelet
- Reduction of the stitch distance
- Reduction of overlapping
- Increase of the stitches in
the round tack
- Reduction of the stitch distance
in the straight bartack
- Reduction of the throw width
in the straight bartack
(see Operating Instructions
“Altering the buttonhole program”):
Inform the service personnel, if
required.

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