Page 1 Operating Instructions...
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, including extracts, is prohibited without the prior written approval of Dürkopp Adler AG. Copyright © Dürkopp Adler AG 2016...
Page 3: Table Of Contents
5.4.6 Using file filters ................47 5.4.7 Entering text ................48 5.4.8 Entering parameter values ............49 5.4.9 Switching on and off the full-screen display ....... 50 5.4.10 Switching on and off zoom ............50 Operating Instructions 906 - 02.0 - 11/2016...
Page 4 Electrical connection..............108 Pneumatic connection .............. 109 Oil lubrication ................110 Performing a test run ..............112 Transporting the machine ............114 Decommissioning..............115 Decommissioning the machine..........115 Dismantling the automatic stacker..........116 Operating Instructions 906 - 02.0 - 11/2016...
Page 5 Customer Service ..............123 12.2 Messages of the software............123 12.2.1 Information messages .............. 124 12.2.2 Error messages ................ 124 12.2.3 Errors in sewing process ............128 Technical data................. 131 Appendix ................. 135 Operating Instructions 906 - 02.0 - 11/2016...
Page 6 Table of Contents Operating Instructions 906 - 02.0 - 11/2016...
Page 7: About These Instructions
Proper setting Specifies proper setting. Disturbances Specifies the disturbances that can occur from an incorrect setting. Cover Specifies which covers must be disassembled in order to access the com- ponents to be set. Operating Instructions 906 - 02.0 - 11/2016...
Page 8 Safety ( p. 9). If no other clear location information is used in a figure, indications of right Location information or left are always from the user's point of view. Operating Instructions 906 - 02.0 - 11/2016...
Page 9: Other Documents
Leave machines, equipment and packaging material in the condition in which they were found when the damage was discovered. This will ensure any claims against the transport company. Report all other complaints to Dürkopp Adler immediately after receiving the product. Operating Instructions 906 - 02.0 - 11/2016...
Page 10 About these instructions Operating Instructions 906 - 02.0 - 11/2016...
Page 11: Safety
• set up the machine • perform maintenance work and repairs • perform work on electrical equipment Only authorized persons may work on the machine and must first have understood these instructions. Operating Instructions 906 - 02.0 - 11/2016...
Page 12: Signal Words And Symbols Used In Warnings
If ignored, environmental damage can result NOTICE (without hazard symbol) If ignored, property damage can result The following symbols indicate the type of danger to personnel: Symbols Symbol Type of danger General Electric shock Puncture Operating Instructions 906 - 02.0 - 11/2016...
Page 13 Type and source of danger! Consequences of non-compliance. Measures for avoiding the danger.  This is what a warning looks like for a hazard that could result in moderate or minor injury if the warning is ignored. Operating Instructions 906 - 02.0 - 11/2016...
Page 14 NOTICE Type and source of danger! Consequences of non-compliance. Measures for avoiding the danger.  This is what a warning looks like for a hazard that could result in property damage if ignored. Operating Instructions 906 - 02.0 - 11/2016...
Page 15: Machine Description
(6) - Protective bar (12) - Control operating terminal Fig. 2: Components of the machine (2) ① ② ③ (1) - Compressed air gun (3) - Main switch (2) - Compressed air maintenance unit Operating Instructions 906 - 02.0 - 11/2016...
Page 16: Proper Use
Dürkopp Adler cannot be held liable for damages resulting from improper use. 3.3 Declaration of Conformity The machine complies with European regulations ensuring health, safety, and environmental protection as specified in the declaration of conformity or in the declaration of incorporation. Operating Instructions 906 - 02.0 - 11/2016...
Page 17: Operation
After referencing, the startup screen is displayed on the operating ter- minal for a few seconds. Information On the start screen, you can set the language for the user interface in the Language menu or open the Service menu ( p. 41). Operating Instructions 906 - 02.0 - 11/2016...
Page 18: Switching On And Off Threading Mode
Abb. 4: Switching on and off threading mode ③ ① ② (1) - Drive carriage (3) - Threading mode push button (2) - Hook cover Operating Instructions 906 - 02.0 - 11/2016...
Page 19: Switching On Quick-Stop
You must always switch the machine off at the main switch before performing any maintenance or cleaning work. The Quick-stop switch (1) can be used to immediately stop all working steps on the machine, e.g. after an operating error. Operating Instructions 906 - 02.0 - 11/2016...
Page 20 Abb. 6: Switching on Quick-stop (2) ② (2) - Main switch 1. Turn the main switch (2) to the left into the 0 position.  All drives and the control are immediately disconnected from the mains grid. Operating Instructions 906 - 02.0 - 11/2016...
Page 21: Sewing On Pre-Bound Pockets
• The transfer plate transfers the sewing material to the clamp and moves back into its starting position. • The sews the pre-bound pocket onto the sewing material. • The automatic stacker places the sewn product onto the bundle mount. Operating Instructions 906 - 02.0 - 11/2016...
Page 22 Removing the bundle from the tray on the automatic stacker The machine will stop when the tray on the automatic stacker is full. A message on the screen indicates that you should remove the bundle. Operating Instructions 906 - 02.0 - 11/2016...
Page 23: Swiveling The Machine Head
Risk of injury from moving parts! Crushing possible. Switch off the machine at the main switch before swiveling up the machine head and performing maintenance. The machine head can be swiveled up for maintenance work. Operating Instructions 906 - 02.0 - 11/2016...
Page 24: Swiveling Up The Machine Head
3. Release the locking lever (4) under the tabletop. 4. Lift the machine head in the head cover region (1) and swivel up carefully.  The latch (5) latches into place. The space under the stand is now accessible. Operating Instructions 906 - 02.0 - 11/2016...
Page 25: Swiveling Down The Machine Head
To swivel down the machine head: 1. Hold the machine head in the head cover region. 2. Release the latch (2). 3. Carefully swivel down the machine head. 4. Latch the locking lever (1) under the tabletop. Operating Instructions 906 - 02.0 - 11/2016...
Page 26: Inserting/Changing The Needle
5. Tighten the hexagon screw (3). Order NOTICE Property damage may occur! Risk of damage to machine and thread if hook distance is incorrect. After switching to a different needle thickness, adjust the distance between needle and hook. Operating Instructions 906 - 02.0 - 11/2016...
Page 27: Threading The Needle Thread
(11) - Guide (6) - Diverter To thread the needle thread: 1. Fit the thread reel on the reel stand. 2. Guide the needle thread through a hole in the guide on the thread guide. Operating Instructions 906 - 02.0 - 11/2016...
Page 28 11. Insert the thread through the needle thread monitor(12) and the thread clamp (13). 12. Insert the thread through the guides (14) and (15). 13. Insert the thread through the needle eye in such a way that the loose thread end faces the hook. Operating Instructions 906 - 02.0 - 11/2016...
Page 29: Setting The Thread Regulator
2. Move the thread regulator (3): • Lower thread quantity: Slide the thread regulator (3) to the right. • Larger thread quantity: Slide the thread regulator (3) to the left. 3. Tighten the fastening screw (2). Operating Instructions 906 - 02.0 - 11/2016...
Page 30: Winding The Hook Thread
5. Plug an empty bobbin on the winding shaft (4) and turn clockwise until it clicks into place. 6. Feed the thread to the winder, clamp the thread behind the cutter and tear the thread off. Operating Instructions 906 - 02.0 - 11/2016...
Page 31: Changing The Bobbin
1. Press the threading mode (1) push button.  The drive carriage moves to the bobbin change position. The cover plate (2) swivels to the side. The sewing feet are moved to the lower position. The lighting is switched on. Operating Instructions 906 - 02.0 - 11/2016...
Page 32 Information If the bobbin has been changed because it was empty, the thread consumption will be counted from full bobbin capacity after a bobbin change. Operating Instructions 906 - 02.0 - 11/2016...
Page 33: Thread Tension
(3) - Needle thread tension higher than hook thread tension 4.11.1 Setting the needle thread tension The needle thread tension can only be set using the software of the control panel; for detailed information, refer to the chapter Programming ( p. 55). Operating Instructions 906 - 02.0 - 11/2016...
Page 34: Setting The Hook Thread Tension
Abb. 21: Setting the hook thread tension (2) ③ ④ (3) - Tension spring (4) - Adjusting screw The hook thread tension is generated by the tension spring (3) and adjust- ed via the adjustment screw (4). Operating Instructions 906 - 02.0 - 11/2016...
Page 35: Changing The Configuration Set
To change the configuration set, you must activate the clamp change mode. Abb. 22: Changing the configuration set ① ③ ② (1) - Inner slider (3) - Transfer plate (2) - Outer frame Operating Instructions 906 - 02.0 - 11/2016...
Page 36: Activating The Clamp Change Mode
The installation takes place in reverse order. Disassembling the outer frame and inner slider Abb. 24: Disassembling the outer frame and inner slider ① ② (1) - Outer frame (2) - Inner slider Operating Instructions 906 - 02.0 - 11/2016...
Page 37 1. Spread the inner slider (1), slide as far as the stopper (3) into the bracket and hold it in this position. Important The guide drill hole of the slider must be positioned in the pin of the driver (2). The inner slider must remain fully apart. Operating Instructions 906 - 02.0 - 11/2016...
Page 38: Changing The Transfer Plate
1. Slide the outer frame (1) as far as the stopper (2) into the bracket and hold it in this position. 2. Tap the 2 button on the screen.  The transfer plate is closed. Operating Instructions 906 - 02.0 - 11/2016...
Page 39 1. Slide the transfer plate (1) as far as the stopper (2) into the bracket and hold it in this position. 2. Tap the 3 button on the screen.  The transfer plate is closed. Operating Instructions 906 - 02.0 - 11/2016...
Page 40: Ending Clamp Change Mode
( p. 50). Important The contour must be within the boundaries of the sewing field. Open an appropriate sequence for the configuration set ( p. 50). Operating Instructions 906 - 02.0 - 11/2016...
Page 41: Programming
During sewing, these programs are called up and processed stitch by stitch. The software is also used to define general settings that apply to all programs. The software also includes technical menu items for testing and maintain- ing the machine. Operating Instructions 906 - 02.0 - 11/2016...
Page 42: Overview Of The Menu Structure
Machine parameters  p. 74 for all programs or Sequence  p. 74 modify an existing Seam program Parameter  p. 69 program. Contour adjustment  p. 66 Testing Contour  p. 60 Operating Instructions 906 - 02.0 - 11/2016...
Page 43: Starting The Software
After this, the start screen is shown on the operating terminal for a few seconds. Abb. 30: Starting the software (1) ② ① (1) - Language selection button (2) - Service Operating Instructions 906 - 02.0 - 11/2016...
Page 44 (10) is displayed at the right. In the various menus, this bar contains information on the currently selected menu item. Main window (2) The contour to be sewn is displayed here. Operating Instructions 906 - 02.0 - 11/2016...
Page 45 - Number of stitches/hook thread consumed Button for Repair mode (9) This button is used to switch the Repair mode on and off. The current status (On / Off) is displayed in the button. Operating Instructions 906 - 02.0 - 11/2016...
Page 46: Basic Functions For Using The Software
• The window is closed and the entered or selected data is adopted. In windows with data entry or selection fields: Abort • The window is closed and the entered or selected data is discarded. Operating Instructions 906 - 02.0 - 11/2016...
Page 47: Display Principles
Buttons that are not used in the current context are grayed-out (1). 5.4.4 Scrolling the display Abb. 34: Scrolling the display ① (1) - Scrollbar A scrollbar (1) appears at the right side when a displayed image is larger than the screen height. Operating Instructions 906 - 02.0 - 11/2016...
Page 48: Selecting Options From A List
Abb. 36: Selection with checkboxes ① (1) - Checkbox: Selected elements Checkboxes allow you to select multiple entries. 1. Tap the desired checkboxes.  The selected entries (1) are marked with a cross. Operating Instructions 906 - 02.0 - 11/2016...
Page 49: Using File Filters
2. Tap the desired filter criterion: • .fnp911: Seam programs only • .seq911: Sequences only • All Files: Seam programs and sequences 3. Tap the Open button.  The list is updated according to the selected filter: Operating Instructions 906 - 02.0 - 11/2016...
Page 50: Entering Text
1. Tap the Aa (5) button. Deleting the last character 1. Tap the DEL (4) button. Adopting the entered text 1. Confirm with OK (3).  The entered text is adopted, and the text entry window is closed. Operating Instructions 906 - 02.0 - 11/2016...
Page 51: Entering Parameter Values
• Example -12: Enter the value in the order 1, -, 2. Deleting a value 1. Tap the DEL button. Adopting a value 1. Confirm with OK.  The entered value is adopted, and the numeric entry window is closed. Operating Instructions 906 - 02.0 - 11/2016...
Page 52: Switching On And Off The Full-Screen Display
1. Tap the menu items File > Open in the main window.  The selection window appears. All seam programs and sequences are displayed. Information Using File filter, you can limit the selection and make the list more manageable ( p. 47). Operating Instructions 906 - 02.0 - 11/2016...
Page 53: Briefly Sewing With Modified Values
5.6.1 Sewing with a modified thread tension To sew with a modified thread tension: 1. Tap the menu items Correction > Thread tension.  The window for changing the thread tension appears: Operating Instructions 906 - 02.0 - 11/2016...
Page 54: Sewing With A Modified Speed
 The window for changing the thread tension appears: Abb. 43: Sewing with a modified speed 2. Enter the desired speed. 3. Confirm with OK.  The value is adopted and used for all seams until the machine is switched off. Operating Instructions 906 - 02.0 - 11/2016...
Page 55: Fixing A Thread Breakage
5. Use the Forwards and Back buttons to move to the point where sewing is to continue.  The program jumps back to the main screen and sewing of the seam continues from the selected point. Operating Instructions 906 - 02.0 - 11/2016...
Page 56: Continuing A Seam In Repair Mode After An Error
( p. 78). 1. Tap the Reset Counter button on the main screen.  The counter is reset to the value defined in the machine parameters. Operating Instructions 906 - 02.0 - 11/2016...
Page 57: Creating A New Seam Program
2. Use the arrow buttons (2) to move the cursor (3) to the desired starting position. 3. Confirm with OK.  The desired starting point is adopted and marked with a green dot. Operating Instructions 906 - 02.0 - 11/2016...
Page 58 Abb. 47: Creating a new seam program (2) Selecting the seam parameters for the path 5. Tap the respective parameter.  The window for entry opens. 6. Enter the desired value for the parameter ( p. 49). Operating Instructions 906 - 02.0 - 11/2016...
Page 59  The seam path is adopted with the specified parameters. Adding further seam paths Further seam paths are defined using the same procedure. 9. Add each new seam path by starting at step 4 ( p. 56). Operating Instructions 906 - 02.0 - 11/2016...
Page 60: Setting Mode X In Load And Deposit Mode
If you perform a contour test, for example, it makes sense to set Mode 5 in Load and Deposit mode. Mode 5 means: • Load mode: Transfer plate is deactivated • Deposit mode: Stacker is deactivated Operating Instructions 906 - 02.0 - 11/2016...
Page 61 2. Tap the PP2 Load mode/PP3 Deposit mode button. 3. Tap the Mode X button. The Mode X button shows which mode is currently set.  The mode selection window appears. 4. Tap the desired Mode X. 5. Confirm with OK. Operating Instructions 906 - 02.0 - 11/2016...
Page 62: Performing A Contour Test
4. To lower the transfer plate, press the pedal. 5. Tap the menu items Edit > Seam program > Testing Contour.  The Testing Contour window opens. Abb. 49: Performing a contour test Operating Instructions 906 - 02.0 - 11/2016...
Page 63: Creating A Sequence
3. Tap the Insert button.  The seam program is adopted the sequence and is displayed in the Sequence field at the left side of the screen. 4. Add further seam programs in the same manner. Operating Instructions 906 - 02.0 - 11/2016...
Page 64: Editing An Existing Sequence
3. Add programs to the sequence using the Insert button or remove from the sequence using the Delete button. The steps correspond to the procedure used for creating a new sequence ( p. 61). Operating Instructions 906 - 02.0 - 11/2016...
Page 65: Saving A Seam Program/Sequence Under A Different Name
USB key. Information Not all commonly available USB keys are suitable for the copying process. You can obtain a suitable USB key from Dürkopp Adler using the part number 9805 791113. Operating Instructions 906 - 02.0 - 11/2016...
Page 66 Information You can limit the selection with File filter. This makes the list more manageable ( p. 47). 4. Tap the desired file.  The selected file is highlighted with a dark background. Operating Instructions 906 - 02.0 - 11/2016...
Page 67: Deleting A Seam Program Or Sequence
5.18 Editing an existing seam program You can change the contour and parameters of existing seam programs. The changes are applied to the seam program that is currently open on the main screen. Operating Instructions 906 - 02.0 - 11/2016...
Page 68: Adjusting A Contour
(2). Top scale: First stitch of the seam pattern. Bottom scale: Last stitch of the seam pattern. 3. Tap the Go To button.  The selected contour region is displayed in detail. Operating Instructions 906 - 02.0 - 11/2016...
Page 69 6. Use the arrow buttons to move the stitching point to the new position (4).  The modified seam path is displayed in green. 7. Tap the Next button.  The window for selecting the technology operations opens.  Operating Instructions 906 - 02.0 - 11/2016...
Page 70 Ensure that only sequences and seam programs which are suitable for the configuration set are used. Abb. 59: Adjusting a contour (5) Operating Instructions 906 - 02.0 - 11/2016...
Page 71: Changing Parameters
 The window for modifying the parameter opens. 4. Set the parameter to the desired value ( p. 49). There are 8 program parameter groups: Symbol Parameter group PP1 - Configuration General settings Operating Instructions 906 - 02.0 - 11/2016...
Page 72 (the barcode reader additional equipment must be activated) Laser marking lamps Up to four laser marking lamps for easier alignment of the sewing material can be controlled (the additional equipment must be activated) Operating Instructions 906 - 02.0 - 11/2016...
Page 73 The default value can be changed for corrections. Loading position X and deposit position X must correspond. Loading position Y The default value can be changed for corrections. Loading position X and deposit position Y must correspond. Operating Instructions 906 - 02.0 - 11/2016...
Page 74 (min. = 0 .. max. = 99; Def. = 5) Is only active if activated in the machine parameters. (A higher value makes the needle monitor less sensitive. 99 = Needle thread monitor switched off in this program only.) Operating Instructions 906 - 02.0 - 11/2016...
Page 75 (min. = 80 .. max. = 120; Def. = 100 %) X center point of scaling (min. = -150.0 .. max. = 150.0; Def. = 0.0 mm) Y center point of scaling (min. = -150.0 .. max. = 150.0; Def. = 0.0 mm) Operating Instructions 906 - 02.0 - 11/2016...
Page 76: Editing Machine Parameters
Limit values for speeds and positions MP3 - Needle thread monitor Behavior after thread breakage MP4 - Thread cutting Speed, position and tension MP5 - Clamping thread Starting angle MP6 - Counters Settings for program and bobbin counters Operating Instructions 906 - 02.0 - 11/2016...
Page 77 No additional structures are taken into account. Special limitation Individual limits are taken into account. Pedal Raising and lowering the transfer plate. Start buttons By simultaneously pressing both start buttons, the sewing process is started. Operating Instructions 906 - 02.0 - 11/2016...
Page 78 Position of bobbin change X The value range varies depending on the subclass and sewing field size. Position of bobbin change Y The value range varies depending on the subclass and sewing field size. Operating Instructions 906 - 02.0 - 11/2016...
Page 79 (min. = 0 .. max. = 359; Def. = 340 °) Starting angle for opening the thread clamp during the first stitch. If the closing and opening angles are the same then the thread clamp is not activated. Operating Instructions 906 - 02.0 - 11/2016...
Page 80: Checking And Changing The Technical Settings
The technical settings are made via the menu item Extras > Service. Abb. 62: Checking and changing the technical settings A password must always be entered in order to access the menu items in Extras > Service ( p. 44). Operating Instructions 906 - 02.0 - 11/2016...
Page 81: Adjusting The Basic Functions
Password protection of the first action after switching on •  - Comprehensive password protection deactivated: Password protection for the technical menu items only 3. Tap the Activate / Deactivate option to switch between the settings. 4. Confirm with OK. Operating Instructions 906 - 02.0 - 11/2016...
Page 82 To test the touchscreen: 1. In the menu item Extras > Service > Adjustments tap the Touch- Adjustments option. 2. In the following window tap the Touch Test option.  An empty window is opened. Operating Instructions 906 - 02.0 - 11/2016...
Page 83: Displaying System Information
Only for Dürkopp Adler Service personnel Log visualizer List of the last log settings Only for Dürkopp Adler Service personnel State of operation panel Status appears in the log display Only for Dürkopp Adler Service personnel Operating Instructions 906 - 02.0 - 11/2016...
Page 84: Testing Multitest Machine Functions
Dürkopp Adler. To test inputs and outputs: 1. In the Extras > Service > Multi-test menu item, tap the switch- ing outputs elements option.  The IO Test Page window is displayed. Operating Instructions 906 - 02.0 - 11/2016...
Page 85 Inner slider back (reverse) Outer frame up Needle thread monitor Bobbin cover Upper housing lock Residual thread monitor (hook thread) Transfer plate up/down (pedal) Reserve Oil level control sensor Pressure monitor Quick stop Operating Instructions 906 - 02.0 - 11/2016...
Page 86 Outer frame change of shape Inner slider change of shape Left/right transfer plate Transfer plate change of shape Change of shape up/down Reset RTM Throw over pants Barcode reader Eject pants Bracket Bundle removal Reserved for laser Operating Instructions 906 - 02.0 - 11/2016...
Page 87 6. Tap the button.  The sewing motor runs at the entered speed. 7. Tap the button.  The sewing motor stops. 8. Tap the button.  The sewing motor runs at the entered speed. Operating Instructions 906 - 02.0 - 11/2016...
Page 88 Go to position Set the sewing foot height Switch off the power to the drives Manually check the freedom of motion of the sewing foot rod 2. Tap the desired symbol and execute the function. Operating Instructions 906 - 02.0 - 11/2016...
Page 89: Initializing The Control, Performing Updates
To initialize the control and perform an update: 1. Tap the menu items Extras > Service > Initialization and update.  The screen for initialization and update appears. Abb. 68: Initializing the control and performing an update Operating Instructions 906 - 02.0 - 11/2016...
Page 90 You can obtain a suitable USB key from Dürkopp Adler using the order number 9805 791113. To perform an update of the control: 1. Switch off the machine. 2. Insert the USB key into the USB port (1) on the operating terminal. Operating Instructions 906 - 02.0 - 11/2016...
Page 91 (1) - Menu Info 1. Tap menu items ? > Tap on Info (1).  The following information is displayed: • Class • Subclass • Version number, date of creation of this software version Operating Instructions 906 - 02.0 - 11/2016...
Page 92 Programming Operating Instructions 906 - 02.0 - 11/2016...
Page 93: Creating Programs With Da-Cad 5000
Selecting the class The first step is to select the class. Abb. 71: Selecting the class Creating the seam contour The next step is to draw the seam contour. Abb. 72: Creating the seam contour Operating Instructions 906 - 02.0 - 11/2016...
Page 94 1. Select the menu items Data transfer > USB memory stick > Save (PC->>USB).  After successfully saving to the USB key, the program can be transferred to the machine ( p. 93). Operating Instructions 906 - 02.0 - 11/2016...
Page 95 3. Adjust the program parameters (especially the sewing foot height,  p. 69). 4. Perform a contour test to check the clamp motion ( p. 60).  Sewing with the program can begin after successful testing/adjustment. Operating Instructions 906 - 02.0 - 11/2016...
Page 96 Creating programs with DA-CAD 5000 Operating Instructions 906 - 02.0 - 11/2016...
Page 97: Maintenance
Check the toothed rack and gear pinion • Check and clean toothed belt • Clean rotation spline shaft • Clean linear guides • Lubricate linear guides Infeed device • Clean and lubricate linear guide Operating Instructions 906 - 02.0 - 11/2016...
Page 98: Cleaning
Lint and thread remnants can impair the operation of the machine. Clean the machine as described. NOTICE Property damage from solvent-based cleaners! Solvent-based cleaners will damage paintwork. Use only solvent-free substances for cleaning. Operating Instructions 906 - 02.0 - 11/2016...
Page 99: Lubricating
If oil has come into contact with your skin, wash the affected areas thoroughly. NOTICE Property damage from incorrect oil! Incorrect oil types can result in damage to the machine. Only use oil that complies with the data in the instructions. Operating Instructions 906 - 02.0 - 11/2016...
Page 100 9047 000013 9047 000014 Warning messages for oil level that is too low • The lamp in the oil reservoir (1) lights up red. • A warning message is displayed on the screen. Operating Instructions 906 - 02.0 - 11/2016...
Page 101: Servicing The Pneumatic System
Refer to the Technical data ( p. 131) chapter for the permissible operating pressure. The operating pressure cannot deviate by more than ± 0.5 bar. Check the operating pressure on a daily basis. Operating Instructions 906 - 02.0 - 11/2016...
Page 102: Draining The Water Condensation
Water condensation accumulates in the water separator (2) of the pressure controller. Proper setting Water condensation must not rise up to the level of the filter element (1). Check the water level in the water separator (2) on a daily basis. Operating Instructions 906 - 02.0 - 11/2016...
Page 103: Cleaning The Filter Element
6. Connect the machine to the compressed air supply. 7.3.3 Cleaning the filter element NOTICE Damage to the paintwork from solvent-based cleaners! Solvent-based cleaners damage the filter. Use only solvent-free substances for washing out the filter tray. Operating Instructions 906 - 02.0 - 11/2016...
Page 104: Parts List
9. Tighten the drain screw (3). 10. Connect the machine to the compressed air supply. 7.4 Parts list A parts list can be ordered from Dürkopp Adler. Or visit our website for further information at: www.duerkopp-adler.com Operating Instructions 906 - 02.0 - 11/2016...
Page 105: Setup
1. Check that all parts are present before setup. Abb. 79: Checking the scope of delivery (1) ① ② ③ ④ ⑤ (1) - Reel stand (4) - Stand (2) - CNC (5) - Pedal (3) - Automatic stacker Operating Instructions 906 - 02.0 - 11/2016...
Page 106: Removing The Transport Locks
• Additional equipment (optional) 8.2 Removing the transport locks 1. Remove all transport locks before setting up the machine: • Polystyrene • Cardboard • Tapes • Braces Important Keep transport locks for future transport. Operating Instructions 906 - 02.0 - 11/2016...
Page 107: Setting Up The Machine
3. Loosen the stand feet (2) so that the frame stands horizontally, evenly and stable on all 4 stand feet (2). 4. Tighten the counternuts (1) on all 4 stand feet (2). 5. Remove the lifting carriage or forklift. Operating Instructions 906 - 02.0 - 11/2016...
Page 108: Assembling The Automatic Stacker
8. Attach the plugs of the valve control lines (6). 9. The allocation is clear from the labeling. 10. Connect the compressed air hose on the valve block to the pneumatic connection (5). Operating Instructions 906 - 02.0 - 11/2016...
Page 109: Assembling The Reel Stand
The pedal can be freely positioned in front of the machine as far as the cable allows. Abb. 84: Pedal setup ① (1) - Pedal To set the pedal: 1. Position the pedal (1) so that the pedal and machine can be operated comfortably. Operating Instructions 906 - 02.0 - 11/2016...
Page 110: Electrical Connection
1. Connect the mains plug: 230 V – 50/60 Hz. Sewing motor direction of rotation It is not necessary to check the direction of rotation. The direction of rota- tion is set automatically by the control. Operating Instructions 906 - 02.0 - 11/2016...
Page 111: Pneumatic Connection
In the case of excessive pressure drop What to do in the event of an excessive pressure drop: 1. Increase the compressor power. 2. Increase the diameter of the compressed air supply line. Operating Instructions 906 - 02.0 - 11/2016...
Page 112 2. Set the operating pressure in such a way that the pressure indicator (2) displays 6 bar: • To increase the pressure: Turn the adjustment knob (1) clockwise. • To reduce the pressure: Turn the adjustment knob (1) counterclockwise. 3. Push the adjustment knob (1) down. Operating Instructions 906 - 02.0 - 11/2016...
Page 113: Oil Lubrication
Only use oil that complies with the data in the instructions. For lubricating the machine, use only lubricating oil DA 10 or oil of equiv- alent quality with the following specifications: • Viscosity at 40 °C: 10 mm²/s • Flash point: 150 °C Operating Instructions 906 - 02.0 - 11/2016...
Page 114 1. Switch off the machine at the main switch. 2. Check the quantity of oil in the reservoir (1). 3. Pour in oil through the filling point (2) as required: 4. Switch on the machine at the main switch. Operating Instructions 906 - 02.0 - 11/2016...
Page 115: Performing A Test Run
3. Thread hook thread ( p. 28). 4. Switch on the machine at the main switch.  The control is initialized. 5. Press both start buttons.  The reference run starts. The transport carriage moves to the reference position. Operating Instructions 906 - 02.0 - 11/2016...
Page 116: Transporting The Machine
NEVER transport the machine without the transport locks. How to transport the machine to the set-up location: 1. Transport the machine to the set-up location in its original packaging using a stable lifting carriage. Operating Instructions 906 - 02.0 - 11/2016...
Page 117: Decommissioning
6. Cover the control to protect it from soiling. 7. Cover the entire machine if possible to protect it from contamination and damage. Information Observe the necessary safety precautions for transport, ( p. 117). Operating Instructions 906 - 02.0 - 11/2016...
Page 118: Dismantling The Automatic Stacker
8. Remove six threaded screws (2) (screwdriver width 10 mm) and cover plate (3). 9. Remove the automatic stacker from the bracket, rotate 180 ° (the protective bar is at the bottom) and carefully put aside. Operating Instructions 906 - 02.0 - 11/2016...
Page 119: Packaging, Transportation
2. Release the counternuts (1) on all 4 stand feet (2). 3. Rotate the stand feet (2) fully into the frame. 4. Tighten the nuts (1) so that the stand feet (2) remain fixed. Operating Instructions 906 - 02.0 - 11/2016...
Page 120: Packing The Machine
Pack the machine so that it cannot slip or fall over. Select a stable base and fasten the machine to this. Also provide protection from external damage to the machine. Operating Instructions 906 - 02.0 - 11/2016...
Page 121: Transporting The Machine
1. Assembling the transport locks( p. 117) 2. Rotate the stand feet fully upwards ( p. 117). 3. Fasten the carriage with belts. 4. Pack the machine ( p. 118). 5. Transport the machine. Operating Instructions 906 - 02.0 - 11/2016...
Page 122 Packaging, transportation Operating Instructions 906 - 02.0 - 11/2016...
Page 123: Disposal
When disposing of the machine, be aware that it consists of a range of different materials (steel, plastic, electronic components, etc.). Follow the national regulations when disposing these materials. Operating Instructions 906 - 02.0 - 11/2016...
Page 124 Disposal Operating Instructions 906 - 02.0 - 11/2016...
Page 125: Troubleshooting
Waiting for a DAC reset. Wait until the restart has been performed (Duration: several seconds). 8411 DAC program check is active. Wait until the test has been performed (Duration: several seconds). 8414 DAC update succeeded. Operating Instructions 906 - 02.0 - 11/2016...
Page 126 Quick stop switch is activated. Releasing the quick stop switch 9016 Wrong bar code ID Change the program 9100 The counter has not reached the Tap the OK button. The counter is default value. reset. Operating Instructions 906 - 02.0 - 11/2016...
Page 127: Error Messages
• Mains voltage too high • Check the mains voltage 2155 X-axis stepper motor overload • Feed system not moving freely • Eliminate sluggishness • Obstacle to feed motion • Remove obstacles/adjust the motion Operating Instructions 906 - 02.0 - 11/2016...
Page 128 • Mains voltage too high • Check the mains voltage 2355 Stroke position step motor overload • Feed system not moving freely • Eliminate sluggishness • Obstacles to the feed motion • Remove obstacles/adjust the motion Operating Instructions 906 - 02.0 - 11/2016...
Page 129 • Software update • Notify DA Service 4201 Internal CF card defective • Switch off and on the machine • Retrofit/replace control 5301 Program cannot be sewn Copy program to DAC  p. 63 Operating Instructions 906 - 02.0 - 11/2016...
Page 130: Errors In Sewing Process
Close the bobbin case retainer  p. 17 9701 Parallel clamps not lowered • Remove obstacles • Align sensors 9900 Incorrect machine parameters Initialize the data 9901 Incorrect sequences Initialize the data 9902 Incorrect program parameters Initialize the data Operating Instructions 906 - 02.0 - 11/2016...
Page 131 Check the assembly of the reel incorrectly stand  p. 107 Thread tensions are too tight Check thread tensions Throat plate, hook or spread Have parts reworked by qualified have been damaged by the specialists needle Operating Instructions 906 - 02.0 - 11/2016...
Page 132 Needle thread and hook Check threading path thread have not been threaded correctly Needle breakage Needle thickness is Use recommended needle unsuitable for the sewing thickness  p. 131 material or the thread Operating Instructions 906 - 02.0 - 11/2016...
Page 133: Technical Data
Operating pressure [bar] Air consumption with needle cooling Dependent on the setting Length [mm] 1900 Width [mm] 1520 Height [mm] • Without height adjustment 880-910 • With height adjustment 920-1270 Weight (fitted) [kg] Operating Instructions 906 - 02.0 - 11/2016...
Page 134 • Pneumatic drive for the material feeder and the stacker. • The arm shaft is driven by a brushless DC motor • Maximum speed: 3000 min intermittent (depending on the stitch length and material thickness) Operating Instructions 906 - 02.0 - 11/2016...
Page 135 Maximum sewing field size: 210 × 210 mm Lubricating Central oil-wick lubrication system for machine head and hook Number of stitches Recommended number of stitches: 2700/min Stitch length Maximum stitch length: 12.7 mm Operating Instructions 906 - 02.0 - 11/2016...
Page 136 • Working height of the front edge of the table top for operation of the machine while standing: 880 × 910 mm • Table top tilted by 15° towards the operator • Pedal freely movable within the available cable length Operating Instructions 906 - 02.0 - 11/2016...
Page 137: Appendix
Appendix 14 Appendix Fig. 89: Wiring diagram (1) Operating Instructions 906 - 02.0 - 11/2016...
Page 138 Appendix Fig. 90: Wiring diagram (2) Operating Instructions 906 - 02.0 - 11/2016...
Page 139 Appendix Fig. 91: Wiring diagram (3) Operating Instructions 906 - 02.0 - 11/2016...
Page 140 Appendix Fig. 92: Wiring diagram (4) Operating Instructions 906 - 02.0 - 11/2016...
Page 141 Appendix Fig. 93: Wiring diagram (5) Operating Instructions 906 - 02.0 - 11/2016...
Page 142 Appendix Fig. 94: Wiring diagram (6) Operating Instructions 906 - 02.0 - 11/2016...
Page 143 Appendix Fig. 95: Wiring diagram (7) Operating Instructions 906 - 02.0 - 11/2016...
Page 144 Appendix Fig. 96: Wiring diagram (8) Operating Instructions 906 - 02.0 - 11/2016...
Page 145 Appendix Fig. 97: Wiring diagram (9) Operating Instructions 906 - 02.0 - 11/2016...
Page 146 Appendix Fig. 98: Wiring diagram (10) Operating Instructions 906 - 02.0 - 11/2016...
Page 147 Appendix Fig. 99: Wiring diagram (11) " Operating Instructions 906 - 02.0 - 11/2016...
Page 148 Appendix Fig. 100: Wiring diagram (12) Operating Instructions 906 - 02.0 - 11/2016...
Page 149 Appendix Fig. 101: Wiring diagram (13) & & & Operating Instructions 906 - 02.0 - 11/2016...
Page 150 Appendix Fig. 102: Wiring diagram (14) Operating Instructions 906 - 02.0 - 11/2016...
Page 151 Appendix Fig. 103: Pneumatic diagram (1) Operating Instructions 906 - 02.0 - 11/2016...
Page 152 Appendix Fig. 104: Pneumatic diagram (2) Operating Instructions 906 - 02.0 - 11/2016...
Page 154 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...

DURKOPP ADLER 906 Operating Instructions Manual

1 About These Instructions

2 Safety

3 Machine Description

4 Operation

5 Programming

6 Creating Programs with DA-CAD 5000

7 Maintenance

8 Setup

9 Decommissioning

10 Packaging, Transportation

11 Disposal

12 Troubleshooting

13 Technical Data

14 Appendix

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