DURKOPP ADLER 512-211-01 Service Instructions Manual
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DURKOPP ADLER 512-211-01 Service Instructions Manual

DURKOPP ADLER 512-211-01 Service Instructions Manual

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512-211-01
Service Instructions
532-211-01

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Summary of Contents for DURKOPP ADLER 512-211-01

  • Page 1 512-211-01 Service Instructions 532-211-01...
  • Page 2 IMPORTANT READ CAREFULLY BEFORE USE KEEP FOR FUTURE REFERENCE All rights reserved. Property of Dürkopp Adler AG and protected by copyright. Any reuse of these contents, inclu- ding extracts, is prohibited without the prior written approval of Dürkopp Adler AG. Copyright ©...

  • Page 3: Table Of Contents

    Switching on the sewing machine ..........37 11.3 Reference the machine .............. 37 11.4 Selecting a sewing pattern ............38 11.5 Scaling axes ................38 11.5.1 Scaling the X-axis ............... 38 11.5.2 Scaling the Y-axis ............... 38 Service Instructions 512-211-01/532-211-01 - 00.0 - 06/2016...
  • Page 4 13.2 Lubrication .................. 64 13.2.1 Checking the oil level..............65 13.2.2 Lubricating with grease............... 67 13.3 Adjusting the lubrication for the hook ......... 69 Appendix ................... 71 14.1 Software error messages ............71 Service Instructions 512-211-01/532-211-01 - 00.0 - 06/2016...
  • Page 5 Table of Contents 14.2 Circuit diagram ................73 Service Instructions 512-211-01/532-211-01 - 00.0 - 06/2016...
  • Page 6 Table of Contents Service Instructions 512-211-01/532-211-01 - 00.0 - 06/2016...

  • Page 7: About This Service Manual

    2. Second step The sequence of the steps must always be followed. • Lists are identified by bullet points. Result of performing an operation  Change to the machine or in the display. Service Instructions 512-211-01/532-211-01 - 00.0 - 06/2016...

  • Page 8: Other Documents

    The manufacturer cannot be held liable for damages resulting from: • Breakage and transport damages • Failure to observe operating manual • Improper use • Unauthorized modifications to the machine • Use of untrained personnel • Use of unapproved replacement parts Service Instructions 512-211-01/532-211-01 - 00.0 - 06/2016...

  • Page 9: Safety Information

    They have to be disposed of correctly and in accordance with the applicable statutory provisions. Only qualified specialists may set up the machine. Anyone setting up the machine must have read the set-up instructions first. Service Instructions 512-211-01/532-211-01 - 00.0 - 06/2016...

  • Page 10: Signal Words And Symbols Used In Warnings

    Signal word Endangerment DANGER Will result in serious injury or death. WARNING Can result in serious injury or death. CAUTION Can result in minor or moderate injury. NOTICE Can result in property damage. Service Instructions 512-211-01/532-211-01 - 00.0 - 06/2016...
  • Page 11 Type and source of risk Consequences of non-observance Measures for avoiding the risk This is what a warning looks like for a hazard that could result in serious injury or even death if not complied with. Service Instructions 512-211-01/532-211-01 - 00.0 - 06/2016...
  • Page 12 This is what a warning looks like for a hazard that could result in environmental damage if not com- plied with. NOTICE Type and source of danger! Consequences of non-compliance. Measures for avoiding the danger. Service Instructions 512-211-01/532-211-01 - 00.0 - 06/2016...

  • Page 13: Work Principles

    Machine damage and malfunctions can be caused by laying the cables incorrectly. Excess cabling may obstruct moving machine parts in their ability to function correctly. This will affect the sewing function and may cause damage. Lay excess cabling as described above. Service Instructions 512-211-01/532-211-01 - 00.0 - 06/2016...

  • Page 14: Removing The Covers

    In order to access the components at the machine bottom section, you must first tilt the machine upper section to the left. Fig. 1: Tilting the machine upper section to the left and setting it upright ① (1) - Machine upper section Service Instructions 512-211-01/532-211-01 - 00.0 - 06/2016...

  • Page 15: Removing And Fitting The Head Cover

    1. Unscrew the eye guard (2). 2. Loosen both screws (1). 3. Remove the head cover (3). Fitting the head cover 1. Fit the head cover (3). 2. Tighten both screws (1). 3. Tighten the eye guard (2). Service Instructions 512-211-01/532-211-01 - 00.0 - 06/2016...

  • Page 16: Removing And Fitting The Arm Cover

    2. Tighten all 6 screws (1) firmly in place. 3.3.4 Removing and fitting the right-hand side cover Fig. 4: Removing and fitting the right-hand side cover ① ② (1) - Screw (2) - Right-hand side cover Service Instructions 512-211-01/532-211-01 - 00.0 - 06/2016...

  • Page 17: Removing And Fitting The Left-Hand Side Cover

    1. Loosen all 3 screws (1). 2. Remove the left-hand side cover (2). Fitting the left-hand side cover 1. Fit the left-hand side cover (2). 2. Tighten all 3 screws (1) firmly in place. Service Instructions 512-211-01/532-211-01 - 00.0 - 06/2016...

  • Page 18: Removing And Fitting The Rear Cover

    1. Loosen all 4 screws (1) on the rear cover (2). 2. Remove the rear cover (2). Fitting the rear cover 1. Fit the rear cover (2). 2. Tighten all 4 screws (1) on the rear cover (2) firmly in place. Service Instructions 512-211-01/532-211-01 - 00.0 - 06/2016...

  • Page 19: Opening And Closing The Hook Flap

    ③ ④ (1) - Springs of the fabric clamp (3) - Screw (2) - Clamp feet (4) - Work surface Removing the throat plate 1. Remove both springs of the fabric clamp (1). Service Instructions 512-211-01/532-211-01 - 00.0 - 06/2016...
  • Page 20 7. Unhinge the thread puller blade connecting rod (5). Fig. 10: Removing and inserting the throat plate (3) ⑦ ⑧ (7) - Throat plate (8) - Screw 8. Loosen all 4 screws (8). 9. Remove the throat plate (7) upwards. Service Instructions 512-211-01/532-211-01 - 00.0 - 06/2016...

  • Page 21: Surfaces On Shafts

    Some shafts have flat surfaces at those points where the components are screwed on. This strengthens the connection and setting work is made ea- sier. Always make sure that the whole screw is seated completely on the sur- face. Service Instructions 512-211-01/532-211-01 - 00.0 - 06/2016...
  • Page 22 Work principles Service Instructions 512-211-01/532-211-01 - 00.0 - 06/2016...

  • Page 23: Adjusting The Light Barriers

    • Damage to fabric, wrinkling • Incorrect needle position, needle jams in the hole • Incorrect transport times • Incorrect thread cutting • Poor sewing results Cover • Remove rear cover ( S. 16). Service Instructions 512-211-01/532-211-01 - 00.0 - 06/2016...

  • Page 24: Adjusting The Left And Right Switching Flags

    Faults caused by an incorrect setting • Damage to the needle • Incorrect needle position Cover • Remove the right-hand side cover ( S. 14). • Remove the left-hand side cover ( S. 15). Service Instructions 512-211-01/532-211-01 - 00.0 - 06/2016...

  • Page 25: Thread Clamp Switching Flag

    The thread clamp switching flag is used as reference by the control unit for the thread clamp. The switching flag is located underneath the throat plate to the right and is factory set. Service Instructions 512-211-01/532-211-01 - 00.0 - 06/2016...

  • Page 26: Adjusting The Hook And Needle Bar

    3. Adjust the height of the needle bar (2) so that the applicable upper marker line (3/4) is aligned with the needle bar bush. When doing this make sure that the needle bar (2) is not twisted. 4. Tighten the screw (1). Service Instructions 512-211-01/532-211-01 - 00.0 - 06/2016...

  • Page 27: Adjusting The Loop Stroke And Needle Guard

    • Damage to the hook • Damage to the needle • Missing stitches • Thread breakage Order Prerequisite: • A straight and undamaged needle must be inserted ( Operating manual, Section 4.7 Changing needles). Service Instructions 512-211-01/532-211-01 - 00.0 - 06/2016...
  • Page 28 4. Twist the driver (3) accordingly. 5. Shift the driver (3) axially so that the needle (5) rests against the driver tip and is easily pushed aside. 6. Insert the cover ring. 7. Tighten the screw (4). Service Instructions 512-211-01/532-211-01 - 00.0 - 06/2016...

  • Page 29: Adjusting The Distance Between The Hook Tip And Needle

    4. Twist the hook path bearing (7) in such a way that it has a clearance of 7.5 mm to the right-hand side. 5. Tighten the safety screw (3) of the eccentric. 6. Tighten the screw (1). Service Instructions 512-211-01/532-211-01 - 00.0 - 06/2016...

  • Page 30: Adjusting The Thread Trimmer

    1. Loosen the screw (3). 2. Set a distance of 18.5 mm between the front of the throat plate and the thread trimmer lever (5). 3. Tighten the screw (3). 4. Loosen the counter blade screws (4). Service Instructions 512-211-01/532-211-01 - 00.0 - 06/2016...
  • Page 31 Adjusting the thread trimmer 5. Move the counter blade and set a distance of 0.5 mm between the needle guide (1) and the counter blade (5). 6. Tighten the counter blade screws (4). Service Instructions 512-211-01/532-211-01 - 00.0 - 06/2016...

  • Page 32: Adjusting The Height Of The Fabric Clamp Lift

    3. Tighten the screw (1). Order After changing the height of the fabric clamp lift always check the setting of the thread wiper as well. Service Instructions 512-211-01/532-211-01 - 00.0 - 06/2016...
  • Page 33 • The two fabric clamping feet do not raise and lower synchronously. Fig. 22: Adjusting the fabric clamping feet ① (1) - Screw Adjusting steps 1. Loosen the screws (1). 2. Align the fabric clamping feet synchronously. 3. Tighten the screws (1). Service Instructions 512-211-01/532-211-01 - 00.0 - 06/2016...

  • Page 34: Adjusting The Thread Wiper

    1.5 mm to the needle and the distance range of 23 to 25 mm when pivoting. When using a thin needle set the distance at 23 mm. 3. Tighten the screw (1). Service Instructions 512-211-01/532-211-01 - 00.0 - 06/2016...

  • Page 35: Adjusting The Thread Regulator

    2. Loosen the fastening screw (2). 3. Move the thread regulator (1): • Larger thread quantity: Turn the regulator counterclockwise • Lower thread quantity: Turn the regulator clockwise 4. Tighten the fastening screw (2). Service Instructions 512-211-01/532-211-01 - 00.0 - 06/2016...

  • Page 36: Adjusting The Winder

    2. Align the actuating lever (4): • Smaller fill quantity: Push towards bobbin. • Larger fill quantity: Push away from bobbin. 3. Tighten the clamping screw (2). Fine adjustment 4. Loosen the adjusting screw (1). Service Instructions 512-211-01/532-211-01 - 00.0 - 06/2016...

  • Page 37: Adjusting The Winding Tension

    • Poor sewing results Fig. 26: Adjusting the winding tension ① (1) - Adjusting knob Adjusting steps 1. Turn the adjusting knob (2): • Greater tension: Turn clockwise • Less tension: Turn counterclockwise Service Instructions 512-211-01/532-211-01 - 00.0 - 06/2016...

  • Page 38: Settings Via Software

    Reset button Deletes an error and restores settings. Ready button with LED Change between programming and sewing mode. LED on = sewing mode LED off = programming mode Error LED LED on = error Service Instructions 512-211-01/532-211-01 - 00.0 - 06/2016...

  • Page 39: Switching On The Sewing Machine

    Program display. 11.3 Reference the machine 1. Press the Ready button.  The LED in the button illuminates. 2. Press the Ready button.  The LED in the button switches off. Service Instructions 512-211-01/532-211-01 - 00.0 - 06/2016...

  • Page 40: Selecting A Sewing Pattern

    1. Press the Selection button until the Y-axis LED illuminates. 2. Press the +/- Function buttons until the value for the Y-axis is reached. 100 % corresponds to the specified dimensions for the selected sewing pattern. Service Instructions 512-211-01/532-211-01 - 00.0 - 06/2016...

  • Page 41: Converting The Buttonhole Gap (Class 532)

    (100 % : preset dimension) * desired value Example Preset dimension in X-direction = 16 mm Desired value in X-direction = 10 mm Value to be set = (100 % : 16 mm) * 10 mm = 62.5 % Service Instructions 512-211-01/532-211-01 - 00.0 - 06/2016...

  • Page 42: Setting The Speed

    1. Press the Selection button until the No. Pattern LED illuminates. 2. Press the +/- Function buttons until the desired sewing pattern number appears in the Function display. 3. Press the Ready button. Service Instructions 512-211-01/532-211-01 - 00.0 - 06/2016...

  • Page 43: Winding

    If the pedal is released, the clamp is raised. 3. Briefly press the foot pedal completely forwards.  The sewing process starts. At the end of sewing the clamp is auto- matically raised. Service Instructions 512-211-01/532-211-01 - 00.0 - 06/2016...

  • Page 44: Counter

    3. Press the Ready button to confirm the sewing pattern. 4. Press the +/- Function buttons to change between 0 and 1. 5. Press the Ready button to confirm the value. 6. Press the Memory button. Service Instructions 512-211-01/532-211-01 - 00.0 - 06/2016...

  • Page 45: Storing Sewing Patterns

    • Press the +/- Function button and set the values: -4 /+4. 8. Press the Ready button to confirm the settings. 9. Press the Memory button to quit the memory mode. 10. Check the sewing pattern ( S. 40). Service Instructions 512-211-01/532-211-01 - 00.0 - 06/2016...

  • Page 46: 2Sewing With Memory Buttons

    8. Press the Ready button to confirm the sewing pattern sequence.  The Program display shows the memory slot; the Function display shows the number of sewing patterns. 9. Press the Memory button to quit the memory mode. Service Instructions 512-211-01/532-211-01 - 00.0 - 06/2016...

  • Page 47: Processing Sewing Pattern Sequences

    3. Press the Ready button to confirm the sewing pattern sequence. 4. Press the Reset button to delete the sewing pattern sequence. 5. Press the Ready button to confirm the deletion. 6. Press the Memory button to quit the memory mode. Service Instructions 512-211-01/532-211-01 - 00.0 - 06/2016...

  • Page 48: Stopping Sewing

    5. Press the Reset button to reset a changed value. 6. Press the Ready button to save a change.  The LED in the button switches off. 7. Press the Memory button.  The LED in the button switches off. Service Instructions 512-211-01/532-211-01 - 00.0 - 06/2016...

  • Page 49: 2Editing Parameters In Level M2

    After resetting the parameters to the factory setting, parameter U085 must be set for the button sewing machine. Prerequisite: • The machine is in the programming mode, the LED in the Ready button is off. Service Instructions 512-211-01/532-211-01 - 00.0 - 06/2016...

  • Page 50: Editing Sewing Patterns Externally

    To subsequently move the sewing pattern, see chapter storing sewing patterns ( S. 43). Fig. 28: Example of stitch coordinates in MS Excel or a text editor ① ② (1) - Starting point/first stitch (2) - End point/last stitch Service Instructions 512-211-01/532-211-01 - 00.0 - 06/2016...

  • Page 51: Working With A Usb Stick

    2. Press the USB button. 3. The LED in the button illuminates; the Program display shows para- meter number U01. 4. Press the +/- Program buttons and select a memory slot (U01 ~ U10). Service Instructions 512-211-01/532-211-01 - 00.0 - 06/2016...
  • Page 52 Deleting a sewing pattern on the controller: Value 3 1. Press the +/- Function buttons to set value 3. 2. Press the Selection button. 3. Press the Reset button to confirm the deletion.  The Function display shows "----". Service Instructions 512-211-01/532-211-01 - 00.0 - 06/2016...

  • Page 53: Error Messages

    "0" 3 0 Error needle The needle bar is not at the Check the connections. bar position top top position Turn the needle bar to the top dead center posi- tion. Service Instructions 512-211-01/532-211-01 - 00.0 - 06/2016...
  • Page 54 5 1 0 File error own U01 ~ U10 read error Check file type. sewing patterns Save data to USB again. 5 1 1 USB write error File with the same name Delete or rename file. already exists Service Instructions 512-211-01/532-211-01 - 00.0 - 06/2016...
  • Page 55 Set main switch to OFF. catcher search does not respond Check sensor. 9 1 4 Error thread Thread catcher motor does Set main switch to OFF. catcher motor not operate correctly Check motor and connection. Service Instructions 512-211-01/532-211-01 - 00.0 - 06/2016...

  • Page 56: Loading Software Via A Usb Stick

    1. Switch on the controller.  The current software version is briefly displayed. 2. Insert the USB stick. 3. Press the USB button and wait approx. 3 seconds. 4. Press the Memory button. Service Instructions 512-211-01/532-211-01 - 00.0 - 06/2016...

  • Page 57: 3Setting Parameter U085 (Class 532)

    • A X.XX = Sewing patterns 4. Press the +/- Function buttons and check the respective software ver- sion. 5. Press the Ready button. 6. Press the Memory button.  The LED in the button switches off. Service Instructions 512-211-01/532-211-01 - 00.0 - 06/2016...

  • Page 58: Service Settings Via Software

    Saves/loads a sewing pattern to/from a USB stick. Needle thread clamp button with LED Fixes needle thread during the first stitch. LED on = needle thread clamp on LED off = needle thread clamp off Service Instructions 512-211-01/532-211-01 - 00.0 - 06/2016...

  • Page 59: Accessing The Technician Level

     The controller beeps 1x; the LED in the button illuminates. The Program display shows the parameter numbers; the Function display shows the parameter values. 2. Press the +/- Program buttons to select other parameters. Service Instructions 512-211-01/532-211-01 - 00.0 - 06/2016...

  • Page 60: Editing Parameters In Level 2

     The controller beeps 2x; the LED in the button illuminates. The Program display shows the parameter numbers; the Function display shows the values. 2. Press the +/- Program buttons and select parameter U099. Service Instructions 512-211-01/532-211-01 - 00.0 - 06/2016...
  • Page 61 • Case B: The setting is wrong; the thread puller blade overlaps the needle guide: Adjust blade sensor downwards. • Case C: The setting is correct. 6. Press button P1.  The thread trimmer sensor disk travels to position again. Service Instructions 512-211-01/532-211-01 - 00.0 - 06/2016...
  • Page 62 8. Press the Ready button to save the change.  The LED in the button switches off. 9. Press the Memory button.  The LED in the button switches off. Service Instructions 512-211-01/532-211-01 - 00.0 - 06/2016...

  • Page 63: Loading Software Via A Usb Stick

    8. Remove the USB stick. 12.4.2 Loading sewing patterns 1. Switch on the controller.  The current software version is briefly displayed. 2. Insert the USB stick. 3. Press the USB button and wait approx. 3 seconds. Service Instructions 512-211-01/532-211-01 - 00.0 - 06/2016...

  • Page 64: Setting Parameter U085 (Class 532)

    • A X.XX = Sewing patterns 4. Press the +/- Function buttons and check the respective software ver- sion. 5. Press the Ready button. 6. Press the Memory button.  The LED in the button switches off. Service Instructions 512-211-01/532-211-01 - 00.0 - 06/2016...

  • Page 65: Maintenance

    Points that need to be cleaned particularly thoroughly: • Area under the throat plate (1) • Area around the hook (2) • Bobbin housing and interior • Thread cutter • Area around the needle Service Instructions 512-211-01/532-211-01 - 00.0 - 06/2016...

  • Page 66: Lubrication

    For lubricating the sewing automat, use only lubrication oil DA-10 or oil of equivalent quality with the following specifications: • Viscosity at 40°C: 10 mm²/s • Flash point: 150° C DA-10 can be obtained from DÜRKOPP ADLER AG sales offices using Service Instructions 512-211-01/532-211-01 - 00.0 - 06/2016...

  • Page 67: Checking The Oil Level

    The oil level in the oil reservoir (1) must not drop below the lower red mar- king or be above the upper red marking. 1. Fill oil through the oil filler opening (2) up to the upper red marking. Service Instructions 512-211-01/532-211-01 - 00.0 - 06/2016...
  • Page 68  For lubricating the gear maximum 110 ml are necessary. Fig. 37: Refilling oil ⑤ (5) - Oil gauge glass  When oil splashes at the oil gauge glass during operation enough oil is filled in. Service Instructions 512-211-01/532-211-01 - 00.0 - 06/2016...

  • Page 69: Lubricating With Grease

    (5) - Guide groove 3. Apply a small amount of grease to the inner guide groove (5) and the roller (4) from the outside. 4. Apply a small amount of grease to the joints (6). Service Instructions 512-211-01/532-211-01 - 00.0 - 06/2016...
  • Page 70 (9) - Cross head backside (8) - Groove (10) - Connectors 1. Apply grease to cross head backside (9) and the connectors (10). 2. Lubricate the groove (8). 3. Lubricate the thread lever guide (7). Service Instructions 512-211-01/532-211-01 - 00.0 - 06/2016...

  • Page 71: Adjusting The Lubrication For The Hook

    2. Adjusting the lubricating screw: • Loosening the screw: Increases lubrication for the hook • Tightening the screw: Reduces lubrication for the hook 3. Insert and tighten the screw (1). Service Instructions 512-211-01/532-211-01 - 00.0 - 06/2016...
  • Page 72 Maintenance Service Instructions 512-211-01/532-211-01 - 00.0 - 06/2016...

  • Page 73: Appendix

    • Set main switch to ON. • Reinsert USB stick. 0 6 USB read error Unable to read U01 ~ U10. • Set main switch to OFF. • Set main switch to ON. • Reinsert USB stick. Service Instructions 512-211-01/532-211-01 - 00.0 - 06/2016...
  • Page 74 • Set main switch to OFF. search does not respond • Check sensor. 1 4 Error thread catcher Thread catcher motor does • Set main switch to OFF. motor not operate corrrectly • Check motor and connection. Service Instructions 512-211-01/532-211-01 - 00.0 - 06/2016...

  • Page 75: Circuit Diagram

    Appendix 14.2 Circuit diagram Circuit diagram - Sheet 1 Service Instructions 512-211-01/532-211-01 - 00.0 - 06/2016...
  • Page 76 Appendix Circuit diagram - Sheet 2 Service Instructions 512-211-01/532-211-01 - 00.0 - 06/2016...
  • Page 77 Appendix Circuit diagram - Sheet 3 Service Instructions 512-211-01/532-211-01 - 00.0 - 06/2016...
  • Page 78 Appendix Circuit diagram - Sheet 4 Service Instructions 512-211-01/532-211-01 - 00.0 - 06/2016...
  • Page 79 Appendix Circuit diagram - Sheet 5 Service Instructions 512-211-01/532-211-01 - 00.0 - 06/2016...
  • Page 80 Appendix Service Instructions 512-211-01/532-211-01 - 00.0 - 06/2016...
  • Page 82 DÜRKOPP ADLER AG Potsdamer Straße 190 33719 Bielefeld GERMANY Phone +49 (0) 521 / 925-00 service@duerkopp-adler.com E-mail www.duerkopp-adler.com...

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532-211-01

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