DURKOPP ADLER 911-211 Service Instructions Manual
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DURKOPP ADLER 911-211 Service Instructions Manual

DURKOPP ADLER 911-211 Service Instructions Manual

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Summary of Contents for DURKOPP ADLER 911-211

  • Page 1 911-211 Service 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

    4.6.2 Setting the light barrier ............... 49 4.6.3 Setting the left stop screw ............50 4.6.4 Setting the sewing foot stroke relative to the needle bar stroke ..................52 4.6.5 Setting the sewing foot height ............ 53 Service Instructions 911-211 - 02.0 - 10/2016...
  • Page 4 Replacing the hook thread bobbin ..........107 Continuing a seam in Repair mode after an error..... 108 Resetting the counter ............... 109 6.10 Creating a new seam program ..........109 6.11 Performing a contour test ............113 Service Instructions 911-211 - 02.0 - 10/2016...
  • Page 5 Technical data................. 168 Appendix ................. 170 13.1 Wiring diagram ................ 170 13.2 Wiring diagram - remaining thread monitor ......195 13.3 Pneumatic diagram..............196 13.4 Pneumatic diagram for machines with remaining thread monitor..................197 Service Instructions 911-211 - 02.0 - 10/2016...
  • Page 6 Table of Contents Service Instructions 911-211 - 02.0 - 10/2016...

  • 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. Service Instructions 911-211 - 02.0 - 10/2016...
  • Page 8 Safety ( p. 10). 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. Service Instructions 911-211 - 02.0 - 10/2016...

  • 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. Service Instructions 911-211 - 02.0 - 10/2016...
  • Page 10 About these instructions Service Instructions 911-211 - 02.0 - 10/2016...

  • 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 un- derstood these instructions. Service Instructions 911-211 - 02.0 - 10/2016...

  • 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 Service Instructions 911-211 - 02.0 - 10/2016...
  • 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. Service Instructions 911-211 - 02.0 - 10/2016...
  • 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. Service Instructions 911-211 - 02.0 - 10/2016...

  • Page 15: Working Basis

    1. Lay any excess cabling neatly in proper cable snakes. 2. Bind together the cable loops with cable ties. Tie loops wherever possible to fixed parts. Important The cables must be secured firmly! 3. Cut off any overlapping cable ties. Service Instructions 911-211 - 02.0 - 10/2016...

  • Page 16: Removing And Opening Covers

    To swivel up the machine head: 1. Release the locking lever (1) under the tabletop. 2. Lift the machine head in the head cover area (2) and swivel up carefully.  The latch (4) latches into place. Service Instructions 911-211 - 02.0 - 10/2016...

  • Page 17: Removing And Assembling The Motor Cover

    To remove the motor cover: 1. Loosen both screws (1). 2. Remove the motor cover (2). Placing the motor cover To place the motor cover: 1. Place the motor cover (2). 2. Tighten both screws (1). Service Instructions 911-211 - 02.0 - 10/2016...

  • Page 18: Removing And Placing The Arm Cover

    4. Press down the hand crank (5) and check for ease of movement; adjust the arm cover position if necessary.  The hand crank (5) must disengage. 5. Place the motor cover (1). Service Instructions 911-211 - 02.0 - 10/2016...

  • Page 19: Removing And Placing The Head Cover

    To remove the head cover: 1. Loosen the screws (1). 2. Remove the head cover (2). Placing the head cover To place the head cover: 1. Place the head cover (2). 2. Tighten the screws (1). Service Instructions 911-211 - 02.0 - 10/2016...

  • Page 20: Removing And Placing The Rear Cover

    1. Loosen all 3 screws (1). 2. Take off the rear cover (2) by moving it back. Placing the rear cover To place the rear cover: 1. Place the rear cover (2). 2. Tighten all 3 screws (1). Service Instructions 911-211 - 02.0 - 10/2016...

  • Page 21: Removing And Placing The Toothed Belt Cover

    1. Loosen all 4 screws (1). 2. Remove toothed belt cover (2). Placing the toothed belt cover To place the toothed belt cover: 1. Place the toothed belt cover (2). 2. Tighten all 4 screws (1). Service Instructions 911-211 - 02.0 - 10/2016...

  • Page 22: Opening And Closing The Bobbin Flap

    3. Press the Threading mode button.  The bobbin flap (1) pivots to the side. Closing the bobbin flap To close the bobbin flap: 1. Release the Threading mode button. 2. Place the sewing material holder. Service Instructions 911-211 - 02.0 - 10/2016...

  • Page 23: Removing And Placing The Sliding Plate

    1. Reach through the hole (2) from below and lift the sliding plate (1). 2. Remove the sliding plate (1). Placing the sliding plate To place the sliding plate: 1. Place the sliding plate (1). Service Instructions 911-211 - 02.0 - 10/2016...

  • Page 24: Removing And Installing The Burner Cover (Optional)

    Fig. 10: Flats on shafts ① ② (1) - Flat (2) - Shaft Some shafts have flats at those points where the components are clamped on to the shaft. This stabilizes the connection and makes setting easier. Service Instructions 911-211 - 02.0 - 10/2016...

  • Page 25: Aligning The Machine Head

    (3) - Flat material (2) - Tabletop Fig. 12: Aligning machine head (2) Order 1. Remove the sliding plate ( p. 22). 2. Check the position of the machine head using the flat material (3). Service Instructions 911-211 - 02.0 - 10/2016...
  • Page 26 5. Check the position of the machine head again. • Front • Carriage at rear position • Carriage at front position Fig. 13: Aligning machine head (3), carriage at rear position Fig. 14: Aligning machine head (4), carriage at front position Service Instructions 911-211 - 02.0 - 10/2016...
  • Page 27 Proper setting The locking mechanism is set correctly if the machine head can be locked in place with ease while not showing any play at the front bearing when moved up and down. Service Instructions 911-211 - 02.0 - 10/2016...
  • Page 28 • lower = turn counterclockwise 9. Test the height of the base plate using flat material (3) and adjust as necessary. 10. Check heights X and adjust as necessary. 11. Check locking mechanism and adjust as necessary. Service Instructions 911-211 - 02.0 - 10/2016...

  • Page 29: Locking The Machine In Place

    (1) - Locking peg (2) - Large arresting groove Locking the machine in place 1. Insert the locking peg (6) with the appropriate end into the slot (5) of the arm shaft crank (4). Service Instructions 911-211 - 02.0 - 10/2016...

  • Page 30: Putting The Machine Into Position

    Fig. 19: Putting the machine into position ① (1) - Hand crank To set the machine into position: Press down and turn the hand crank (1) until the machine is in the setting position. Service Instructions 911-211 - 02.0 - 10/2016...

  • Page 31: Machine Head

    3. Push the arm shaft crank (1) to the right as far as it will go. 4. Tighten all the threaded pins (2) on the arm shaft crank (1). Service Instructions 911-211 - 02.0 - 10/2016...

  • Page 32: Positioning The Toothed Belt Wheels

    16) Fig. 21: Setting the upper toothed belt wheel ① ④ ② ③ (1) - Threaded pins (3) - Upper toothed belt wheel (2) - Flat of arm shaft (4) - Toothed belt Service Instructions 911-211 - 02.0 - 10/2016...

  • Page 33: Setting The Lower Toothed Belt Wheel

    • Toothed belt cover ( p. 20) Fig. 22: Setting the lower toothed belt wheel ① ② ③ ④ (1) - Toothed belt (3) - Lower toothed belt wheel (2) - Edge (4) - Threaded pins Service Instructions 911-211 - 02.0 - 10/2016...

  • Page 34: Aligning The Needle Bar Linkage

     The needle must enter the needle hole precisely in the center. Cover • Head cover ( p. 18) Fig. 23: Aligning the needle bar linkage ① ③ ② (1) - Threaded pins (3) - Needle bar linkage (2) - Throat plate Service Instructions 911-211 - 02.0 - 10/2016...

  • Page 35: Position Of The Hook And Needle

    Fig. 24: Setting the loop stroke position (1) ① ③ ② (1) - Needle (3) - Hook tip (2) - Groove The loop stroke is precisely 2.4 mm. Service Instructions 911-211 - 02.0 - 10/2016...
  • Page 36 5. Remove the lock ( p. 29). Order Then check the following settings: • Position of the needle guard ( p. 40) • Timing of cutting by the thread cutter ( p. 79) Service Instructions 911-211 - 02.0 - 10/2016...

  • Page 37: Setting The Needle Bar Height

    • Damage to the hook tip • Jamming of the needle thread • Missing stitches • Thread breaking • Needle breakage Cover • Head cover ( p. 18) • Bobbin flap ( p. 21) Service Instructions 911-211 - 02.0 - 10/2016...
  • Page 38 7. Place the throat plate (6). 8. Tighten the screws (1).  9. Remove the lock ( p. 29). Order Then check the following setting: • Position of the needle guard ( p. 40) Service Instructions 911-211 - 02.0 - 10/2016...

  • Page 39: Setting The Hook Side Clearance

    Machine locked in place at position 1 ( p. 28).  Maximum 0.1 mm distance between the hook tip and the groove for the needle. Cover • Swivel up the machine head ( p. 15) Service Instructions 911-211 - 02.0 - 10/2016...
  • Page 40 6. Tighten the threaded pins for the clamping ring (1). 7. Check the loop stroke position ( p. 34).  8. Remove the lock ( p. 29). Order Then check the following setting: • Position of the needle guard ( p. 40) Service Instructions 911-211 - 02.0 - 10/2016...

  • Page 41: Setting The Needle Guard

    Proper setting Machine locked in place at position 1 ( p. 28).  The needle guard pushes the needle away just enough so that it is not touched by the hook tip. Service Instructions 911-211 - 02.0 - 10/2016...

  • Page 42: Setting The Needle Guide

    Proper setting 1. Machine locked in place at position 1 ( p. 28).  The needle guard pushes the needle just enough away so that it can- not be touched by the hook tip. Service Instructions 911-211 - 02.0 - 10/2016...
  • Page 43 4. Loosen the screw (4). 5. Move the needle guide (3) as close as possible against the needle. 6. Tighten the screw (4). 7. Check this distance using a piece of paper (5). Service Instructions 911-211 - 02.0 - 10/2016...

  • Page 44: Setting The Bobbin Case Lifter

    Disturbances caused by an incorrect setting: • Thread breaking • Formation of loops on the bottom side of the seam • Loud machine noise Service Instructions 911-211 - 02.0 - 10/2016...

  • Page 45: Setting The Lifting Gap (Standard Hook Bearing)

    5. Tighten the threaded pin (1). 6. Push the cover (3) upwards. 7. Tighten the screw (2). Service Instructions 911-211 - 02.0 - 10/2016...

  • Page 46: Setting The Lifting Gap (Special Hook Bearing For Safety Belts)

    If the hook thread under the seam is too loose when using short stitch lengths, you need to widen the passage between bobbin case lifter and bobbin case. Cover • Swivel up the machine head ( p. 15) Service Instructions 911-211 - 02.0 - 10/2016...
  • Page 47 5. Tighten the threaded pin (3). 6. Push the cover (5) upwards. 7. Tighten the screw (4). Service Instructions 911-211 - 02.0 - 10/2016...

  • Page 48: Setting The Timing For Opening

    3. Slacken the threaded pin (2) and use a hex key to turn the socket-head screw so that the hex key stands exactly vertical. 4. Tighten the threaded pin (2). 5. Insert the plug (1) into the opening. Service Instructions 911-211 - 02.0 - 10/2016...

  • Page 49: Sewing Foot Lift

    3. Move the toothed rack (2) to 16.5 mm below the upper stop. 4. Insert the gear wheel (3) so that the threaded pins (4) are horizontal. 5. Tighten the threaded pins (4). Service Instructions 911-211 - 02.0 - 10/2016...

  • Page 50: Setting The Light Barrier

    3.5 mm. Fig. 36: Setting the light barrier ① ④ 3,5 mm ② ③ (1) - Mounting plate (3) - Screw (2) - Light barrier (4) - Lever Service Instructions 911-211 - 02.0 - 10/2016...

  • Page 51: Setting The Left Stop Screw

    3. Tap on Extras > Service > Multitest > Hublage einstellen (Set stroke position). 4. Tap on Hüpfer/Drücker (Walking foot/presser foot) until the presser foot is selected. 5. Press and turn the hand crank and check that no stroke is performed. Service Instructions 911-211 - 02.0 - 10/2016...
  • Page 52 (2) - Nut (5) - Lifting gear lever (3) - Stop screw To set the left stop screw: 1. Loosen the nut (2). 2. Turn the stop screw (3) accordingly. 3. Tighten the nut (4). Service Instructions 911-211 - 02.0 - 10/2016...

  • Page 53: Setting The Sewing Foot Stroke Relative To The Needle Bar Stroke

    (6) - Stop block Proper setting The lifting gear (2) must be switched on so that it performs a stroke. The stop block (6) must then lie against the right hand stop screw (5). Service Instructions 911-211 - 02.0 - 10/2016...

  • Page 54: Setting The Sewing Foot Height

    To set the height of the sewing foot: 1. Assemble the walking foot. 2. Tap on Extras > Service > Multitest > Hublage einstellen (Set stroke position). 3. Tap on Hüpfer/Drücker (Walking foot/presser foot) until the walking foot is selected. Service Instructions 911-211 - 02.0 - 10/2016...
  • Page 55 5 mm (corresponding to a 4 mm sewing foot stroke). Information The distance between minimum and maximum positions may have to be determined. If one of these settings is changed the other setting must be checked again. Service Instructions 911-211 - 02.0 - 10/2016...

  • Page 56: Setting The Reference Light Barrier Sewing Axis

    5. Turn the needle bar to top dead center and insert the 3 mm end of the locking peg to peg the arm shaft crank to position 2. 6. Loosen the threaded pin (1). Service Instructions 911-211 - 02.0 - 10/2016...

  • Page 57: Setting The Needle Thread Tension

    ② (1) - Screw (2) - Needle thread regulator To set the needle thread regulator: 1. Press and turn the hand crank and monitor the progress of the needle thread around the hook. Service Instructions 911-211 - 02.0 - 10/2016...

  • Page 58: Setting The Thread Tensioning Spring

    Fig. 42: Setting the thread tensioning spring ① ④ ② ③ (1) - Stop collar (3) - Tension disk (2) - Spring (4) - Screw Service Instructions 911-211 - 02.0 - 10/2016...

  • Page 59: Setting The Thread Tension Plate

    7. Turn the disk (3) clockwise, feeling for the stop (until the tension disks lie flush on each other). 8. Use a (lead) pencil to mark 12 o'clock on the disk (3) and turn it approx. 15-30° clockwise. Service Instructions 911-211 - 02.0 - 10/2016...

  • Page 60: Calibrating The Thread Tension Plate

    (6). 3. Input the measured value into the control and confirm it with OK. 4. Perform the measurement and input also for Kalibrierung 2 (Calibration 2) and Kalibrierung 3 (Calibration 3). Service Instructions 911-211 - 02.0 - 10/2016...

  • Page 61: Thread Cutter

    When changing the knives, make sure that you do not lose the washers. Proper setting The thread-pulling knife (2) pivots as close as possible above the hook and is at the same height as the counter blade (1). Service Instructions 911-211 - 02.0 - 10/2016...
  • Page 62 (1) and thread-pulling knife (2) are at the same height. 4. Non-required washers on the top side between the thread-pulling knife (2) and screw (6) should be kept. 5. Screw down the thread-pulling knife (2) using screw (6). Service Instructions 911-211 - 02.0 - 10/2016...

  • Page 63: Setting The Cutoff Curve

    (3) - Clamping ring (8) - Actuating lever (4) - Control cam (9) - Solenoid (5) - Threaded pins To set the cutoff curve: 1. Loosen all 4 threaded pins (2) on the clamping ring (3). Service Instructions 911-211 - 02.0 - 10/2016...
  • Page 64 13. Push the clamping ring (3) to the right as far as it will go and against the control cam (4). Important Check the loop stroke position ( p. 34). 14. Tighten all 4 threaded pins (2) on the clamping ring (3). Service Instructions 911-211 - 02.0 - 10/2016...

  • Page 65: Setting The Cutting Pressure

    (5) - Hook thread clamp (3) - Thread-pulling knife (6) - Screw To set the cutting pressure: 1. Press and turn the hand crank until the thread-pulling knife (3) can be swung out by hand. Service Instructions 911-211 - 02.0 - 10/2016...

  • Page 66: Setting Point In Time For Cutting

    • Bobbin flap ( p. 21) Fig. 49: Setting point in time for cutting (1) - Roller (4) - Threaded pins (2) - Clamping ring (5) - Counter blade (3) - Control cam (6) - Thread-pulling knife Service Instructions 911-211 - 02.0 - 10/2016...
  • Page 67 • Insert the thread into thread-pulling knife (6) and slowly press and turn the hand crank. • Determine the hand crank position at which the thread is cut. • Repeat setting steps 1 – 7 if necessary. Service Instructions 911-211 - 02.0 - 10/2016...

  • Page 68: Thread Burner (Optional)

    ① ② (1) - Threads (2) - Thread burner  Both threads (1) are burnt off and sucked in. The burner (2) is posi- tioned slightly to the left opposite the needle hole. Service Instructions 911-211 - 02.0 - 10/2016...
  • Page 69 Machine head Setting the height Fig. 51: Setting the height (1) ① ② (1) - Threaded pin (2) - Nut Service Instructions 911-211 - 02.0 - 10/2016...
  • Page 70 6. Check the movement sequence. 7. Set the material thickness scanner in relieved condition if necessary: • Loosen the screws (5) and adjust the height of the material thick- ness scanner (6). • Tighten the screws (5). Service Instructions 911-211 - 02.0 - 10/2016...
  • Page 71 When being burnt off, the thread is not under tension. Fig. 54: Setting the needle thread advancing device (1) ① ③ ② (1) - Screwdriver (3) - Needle thread advancing device (2) - Screw Service Instructions 911-211 - 02.0 - 10/2016...
  • Page 72 2. Move the needle thread advancing device (3) such that it passes over the clamp and under the sewing foot when completing its forward motion. 3. Tighten the screw (2). 4. Use the stop screw (4) to limit the swivel angle. Service Instructions 911-211 - 02.0 - 10/2016...
  • Page 73 To set the position of the burner tip: 1. Loosen the screws (1). 2. Adjust the length of the burner tip (2). 3. Tighten the screws (1). 4. Use the screws (3) to make a height adjustment if necessary. Service Instructions 911-211 - 02.0 - 10/2016...
  • Page 74 Fig. 58: Setting the thread suction device ① (1) - Angle bracket with screws Service Instructions 911-211 - 02.0 - 10/2016...

  • Page 75: Setting The Lower Thread Burner

    10. Tighten the screws (3). 11. Set the throttle valves (4, 5). 12. Check and, if necessary, set the movement sequence again. Service Instructions 911-211 - 02.0 - 10/2016...

  • Page 76: Replacing The Thread Burner Tips

    3. Tighten the screws (1). 4. Tap on Extras > Service > Multitest > Fadenbrenner (Thread burner). 5. Use Brenner an (Burner on) to verify that the burner tip is glowing (turns off automatically after 10 s). Service Instructions 911-211 - 02.0 - 10/2016...

  • Page 77: Setting The Thread Advancing Device

    5. Turn the lever (7) so that the threaded pin (9) on the body casting (3) strikes the hook support. 6. Set the distance between the roller (5) and the highest point of the control cam (6) to 0.1 mm. Service Instructions 911-211 - 02.0 - 10/2016...
  • Page 78 ① ② ⑦ ③ ⑥ ④ ⑤ (1) - Magnet armature (5) - Roller (2) - Locking latch (6) - Control cam (3) - Threaded pin (7) - Locking pin (4) - Nut Service Instructions 911-211 - 02.0 - 10/2016...

  • Page 79: Setting The Hook Thread Clamp

    • Swivel up the machine head ( p. 15) • Bobbin flap ( p. 21) Fig. 63: Setting the hook thread clamp ① ② ③ (1) - Magnet armature (3) - Hook thread clamp (2) - Thread advancing device Service Instructions 911-211 - 02.0 - 10/2016...

  • Page 80: Setting The Control Cam Of The Thread Advancing Device

    Switch off the machine before you check and set the control cam of the thread advancing device. Fig. 64: Setting the control cam of the thread advancing device ① ② (1) - Control cam (2) - Threaded pins Service Instructions 911-211 - 02.0 - 10/2016...
  • Page 81 1. Press the hand crank and turn it to the position "thread lever at top dead center". 2. Loosen the threaded pins (2). 3. Rotate the control cam (1). 4. Tighten the threaded pins (2). Service Instructions 911-211 - 02.0 - 10/2016...

  • Page 82: Changing The Cloth Pressure Bar

    1. Loosen the threaded pins (2) and pull the bearing with the gear wheel (1) out towards the front. 2. Dismantle the drive (3). 3. Loosen all 3 screws (4) and remove the drive shaft. 4. Loosen the screw (5). Service Instructions 911-211 - 02.0 - 10/2016...
  • Page 83 Assembling the cloth pressure bar To assemble the cloth pressure bar: 1. Assemble in reverse of removal. Order After the drive (3) has been tightened, set the sewing foot height ( p. 53). Service Instructions 911-211 - 02.0 - 10/2016...

  • Page 84: Sewing Unit

     The machine moves to the test position. The center of the needle is positioned within the test bore (3), and the tip of the needle can be lowered into the bore by turning the arm shaft crank. Service Instructions 911-211 - 02.0 - 10/2016...

  • Page 85: Changing The Drives

    6. Pull off the plate (3) with the motor (4). 7. Remove the toothed belt wheel (2). To do so, loosen the screw on the toothed belt wheel. 8. Loosen the screws (5). 9. Remove the motor (4) from the plate (3). Service Instructions 911-211 - 02.0 - 10/2016...
  • Page 86 7. Check if the toothed belt (1) operates in parallel. If necessary, set parallel operation at the toothed belt wheel. 8. Place the toothed belt cover ( p. 20). 9. Connect the motor plug with the control. Service Instructions 911-211 - 02.0 - 10/2016...

  • Page 87: Changing The X Drive

    The toothed belt tension is set to the optimum value when the belt oscil- lates at 384 Hz. Check the oscillation, for instance, using a device made by Contitech. 4. Tighten all 4 screws (1). 5. Connect the plug (4). Service Instructions 911-211 - 02.0 - 10/2016...

  • Page 88: Changing The Y Drive

    4. Tension the toothed belt (5) using the screw (3) (185 Hz). Information The toothed belt tension is set to the optimum value when the belt oscil- lates at 185 Hz. Check the oscillation, for instance, using a device made by Contitech. Service Instructions 911-211 - 02.0 - 10/2016...

  • Page 89: Checking The Play Between Toothed Rack And Gear Wheel

    2. Turn the nut (3) so that there is no play. 3. Tighten the screw (4). 4. Check the play along the entire length.  The carriage can be moved without excessive play or stiffness. Service Instructions 911-211 - 02.0 - 10/2016...
  • Page 90 Sewing unit Service Instructions 911-211 - 02.0 - 10/2016...

  • Page 91: Programming

    Buttons or functions are activated by tapping the corresponding position on the monitor. Activating a button/selecting an element: 1. Tap the corresponding button or element with your finger or a touch- screen pen. Service Instructions 911-211 - 02.0 - 10/2016...

  • Page 92: Structure Of The Software

    56 programs, copy or delete  Öffnen (Open) p. 43 existing programs.  Neu (New) Nahtprogramm p. 48 (Seam program)  Sequenz (Sequence) p. 52  Speichern unter p. 55 (Save As) Service Instructions 911-211 - 02.0 - 10/2016...
  • Page 93 Continue sewing the contour from a particular Reparatur-Modus p. 47 point (Repair mode)  Allow for a manual bobbin change Spulenwechsel p. 45 (Bobbin change)  Reset counter to a particular value Zählerreset (Reset p. 47 counter) Service Instructions 911-211 - 02.0 - 10/2016...

  • Page 94: Starting The Software

    (See chapters Testing the functions of the machine ( p. 133) and Changing the language ( p. 132)) If you do not tap any buttons, the software automatically switches to the start screen after a few seconds. Service Instructions 911-211 - 02.0 - 10/2016...
  • Page 95 If a sequence is not currently open but rather only a single seam program then this program fills the entire bar. Service Instructions 911-211 - 02.0 - 10/2016...
  • Page 96 The current seam parameters are displayed below the repair mode button • - Dimensions of the seam • - Speed • - Thread tension • - Number of stitches / hook thread consumed Service Instructions 911-211 - 02.0 - 10/2016...
  • Page 97 Button for resetting the counter (7): This button can be used for resetting the counter for the sewn programs or sequences. The current counter value is displayed next to this button. Service Instructions 911-211 - 02.0 - 10/2016...

  • Page 98: General Operation Of The Software

    The password can be changed via the Extras menu ( p. 131). You can delete incorrect entries via the DEL button. 2. Tap the OK button.  The previously selected menu item opens. Service Instructions 911-211 - 02.0 - 10/2016...

  • Page 99: Closing Windows

    (1) - Grayed-out: Deactivated element (2) - Dark background: Activated element The currently activated or selected element is highlighted with a dark background (2). Buttons that are not used in the current context are grayed-out (1). Service Instructions 911-211 - 02.0 - 10/2016...

  • Page 100: Scrolling The Display

    Selection with option buttons Fig. 81: Selection with option buttons ① (1) - Option buttons: Selected element With round option buttons only one of the displayed options can be selected. Service Instructions 911-211 - 02.0 - 10/2016...

  • Page 101: Using File Filters

    You can use the filter functions to make the list more manageable: To use file filters: 1. Tap the File Filter button under the list.  The file filter screen opens. Service Instructions 911-211 - 02.0 - 10/2016...

  • Page 102: Entering Text

    (4) - DEL: Delete a character (2) - Keyboard (5) - Aa: Switch between uppercase/lowercase (3) - OK (CR): Adopt the entered text Entering text 1. Use the keyboard (2) displayed to enter the text. Service Instructions 911-211 - 02.0 - 10/2016...

  • Page 103: Entering Parameter Values

    The prescribed value range (4) for the parameter is displayed below the symbol (3). The current valid value is displayed in the data entry field (5) below the val- ue range (4). Entering a value 1. Tap the desired numeric buttons (6). Service Instructions 911-211 - 02.0 - 10/2016...

  • Page 104: Switching The Full-Screen Display On And Off

    (1) - Full-screen switched off (2) - Full-screen switched on To switch full-screen on and off: 1. Tap the menu items Extras > Vollbild ein/aus (Full-screen on/off)  The display switches to the respective other mode. Service Instructions 911-211 - 02.0 - 10/2016...

  • Page 105: Switching Zoom On And Off

    >  The file selection screen is displayed. All existing seam programs and sequences are displayed. Information Dateifilter (File Filter) You can use the to make the list more manageable ( p. 100). Service Instructions 911-211 - 02.0 - 10/2016...

  • Page 106: Briefly Sewing With Modified Values

    Important If you wish to adopt the changes then you must modify and save the program. Otherwise the values are automatically reset to the previous settings when the machine is switched off. Service Instructions 911-211 - 02.0 - 10/2016...

  • Page 107: Sewing With A Modified Thread Tension

    To sew with a modified speed: Korrektur (Correction) Nähdre- 1. Tap the menu items > hzahl (Speed)  The window for changing the thread tension appears: Fig. 90: Sewing with a modified speed 2. Enter the desired speed. Service Instructions 911-211 - 02.0 - 10/2016...

  • Page 108: Replacing The Hook Thread Bobbin

    3. Use the Vor (Forwards) and Zurück (Back) buttons to move to the point where sewing is to continue. 4. Tap the Weiternähen (Continue Sewing) button.  The program jumps back to the start screen and sewing of the seam continues from the selected point. Service Instructions 911-211 - 02.0 - 10/2016...

  • Page 109: Continuing A Seam In Repair Mode After An Error

    2. Use the Vor (Forwards) and Zurück (Back) buttons to move to the point where sewing is to continue. 3. Tap the Weiternähen (Continue Sewing) button.  The program jumps back to the start screen and sewing of the seam continues from the selected point. Service Instructions 911-211 - 02.0 - 10/2016...

  • Page 110: Resetting The Counter

    (5) - Speichern (Save) button (2) - Cursor (6) - Löschen (Delete) button (3) - Arrow buttons (7) - Parameter button (4) - OK button: Übernahme (Accept) (8) - Linienauswahl (Line selection) button Service Instructions 911-211 - 02.0 - 10/2016...
  • Page 111 A straight path is sewn. • Curved seam: A curve is sewn.  After tapping the button for a straight or curved seam the correspond- ing window for entering the seam parameters for this path opens. Service Instructions 911-211 - 02.0 - 10/2016...
  • Page 112  The window for entering the parameter value opens. 6. Enter the desired value for the parameter ( p. 102). Seam parameters for teach-in Button Meaning Speed Stitch length Thread tension Stroke height Cut thread Service Instructions 911-211 - 02.0 - 10/2016...
  • Page 113  The program is now available under this name for sewing, editing or copying. Important Always perform a contour test after creating a new program ( p. 113). Ensure that the contour lies within the sewing field limits of your particular unit. Service Instructions 911-211 - 02.0 - 10/2016...

  • Page 114: Performing A Contour Test

    Fig. 95: Performing a contour test 2. Move along the contour stitch by stitch using the Vor (Forwards) and Zurück (Back) buttons. 3. Check that all points lie within the sewing field. Service Instructions 911-211 - 02.0 - 10/2016...

  • Page 115: Creating A New Sequence

     The window for entering the sequence name opens. 2. Enter the desired name and adopt the change by pressing OK (( p. 101)).  The sequence is now available under this name for sewing, editing or copying. Service Instructions 911-211 - 02.0 - 10/2016...

  • Page 116: Editing An Existing Sequence

    3. Use the buttons Einfügen (Insert) and Löschen (Delete) to add programs to the sequence or remove programs from the sequence. The steps correspond to the procedure used for creating a new sequence ( p. 114). Service Instructions 911-211 - 02.0 - 10/2016...

  • Page 117: Saving A Seam Program/Sequence Under A Different Name

     The window for entering the new name is opened. 4. Enter the desired name and adopt the change by pressing OK (( p. 101)).  The program or sequence is now also available under this name for sewing, editing or copying. Service Instructions 911-211 - 02.0 - 10/2016...

  • Page 118: Copying A Seam Program Or Sequence

    3. Tap the desired file.  The selected file is highlighted with a dark background. 4. Tap the Datei kopieren (Copy File) button.  The selected file is copied to the USB key or the control. Service Instructions 911-211 - 02.0 - 10/2016...

  • Page 119: Deleting A Seam Program Or Sequence

    To edit an existing seam program: 1. Open the program you wish to modify via the menu items Datei (File) > Öffnen (Open)  The program opens on the start screen. Service Instructions 911-211 - 02.0 - 10/2016...

  • Page 120: Changing The Contour Of A Seam Program

    The first stitch of the seam is at the top and the last stitch is at the bottom. 3. Tap the Go To button.  The selected contour region is displayed in detail. The stitching point (2) to be modified is marked in red. Service Instructions 911-211 - 02.0 - 10/2016...
  • Page 121 Agreeing to this dialog will save the modified contour. Important: Always perform a contour test after modifying a contour to ensure that the new seam path lies within the permissible sewing field ( p. 113). Service Instructions 911-211 - 02.0 - 10/2016...

  • Page 122: Changing The Parameters Of A Seam Program

    Removal mode and position PP4 - Soft start Number of stitches and speed PP5 - Needle thread monitor Sensitivity value for the needle thread monitor PP6 - Thread consumption Values for determining thread consumption Service Instructions 911-211 - 02.0 - 10/2016...
  • Page 123 After every seam (Def.): The needle is reversed after every seam. Needle cooling (On/Off) Activates/deactivates the needle cooling. Adjusting the speed (min. = 10… max. = 200; Def. = 100%) The sewing speed is adjusted by the specified percent value. Service Instructions 911-211 - 02.0 - 10/2016...
  • Page 124 Loading position X The value range varies depending on the subclass and sewing field size. Loading position Y The value range varies depending on the subclass and sewing field size. Service Instructions 911-211 - 02.0 - 10/2016...
  • Page 125 (min.=0..max.= 99: Def. 5) Is only active if activated in the machine parameters. (A higher value makes the needle thread monitor less sensitive. 99 = Needle thread monitor switched off in this program only.) Service Instructions 911-211 - 02.0 - 10/2016...
  • Page 126 (min. = 80… max. = 120; Def. = 100 %) X scaling origin (min. = -150.0… max. = 150.0; Def. = 0.0 mm) Y scaling origin (min. = -150.0… max. = 150.0; Def. = 0.0 mm) Service Instructions 911-211 - 02.0 - 10/2016...

  • Page 127: 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 - Thread clamping Starting angle MP6 - Counters Settings for program and bobbin counters Service Instructions 911-211 - 02.0 - 10/2016...
  • Page 128 Single clamp: One-piece parallel clamp with angle mount Single clamp with hanger (Def.): One-piece parallel clamp with hanger mount Double clamp: Two-piece parallel clamp with angle mount Alternating clamp: Removable clamp Special clamp: Special clamp Service Instructions 911-211 - 02.0 - 10/2016...
  • Page 129 (min. = 0 .. max. 359; Def. 0 degrees, with thread burner 20 degrees) The needle is reversed at this angle in order to increase the clearance to the clamp. Edit time paths This function is only for Dürkopp Adler Service personnel. Service Instructions 911-211 - 02.0 - 10/2016...
  • Page 130 (min. = 0° .. max. 400°; Def. 370°) Starting angle for the thread tension during the cutting stitch. (At an angle greater than 359° the thread tension is activated in the next stitch.) Service Instructions 911-211 - 02.0 - 10/2016...
  • Page 131 Bobbin supply capacity (min. = 0.0 .. max. 400.0; Def. 0.0m) A message is displayed to the user after the bobbin supply capacity has been consumed. A value of 0 deactivates the function. Service Instructions 911-211 - 02.0 - 10/2016...

  • Page 132: Checking And Changing The Technical Settings

     The window for entering the new password appears. 4. Enter the new password( p. 97). Important The password must not have more than 5 digits. 5. Confirm the new password with OK. Service Instructions 911-211 - 02.0 - 10/2016...
  • Page 133 Datum (Date) and Uhrzeit (Time)  The data entry window for date and time is displayed. 2. Enter the date and/or time. 3. Confirm with OK.  The entered values are adopted Service Instructions 911-211 - 02.0 - 10/2016...
  • Page 134 You can use the Extras > Service > Multitest menu item to check the inputs and outputs, test the sewing motor and set the stroke position. Fig. 106: Testing the functions of the machine Service Instructions 911-211 - 02.0 - 10/2016...
  • Page 135 Eingänge / Ausgänge testen (Test inputs / outputs) option.  The IO-Test (IO Test) Seite (Page) window is displayed. Fig. 107: Testing inputs and outputs ① ② (1) - Area for input elements (2) - Area for output elements Service Instructions 911-211 - 02.0 - 10/2016...
  • Page 136 Threading switch lamp on Oil level indicator warning light on Burner transformer on Upper burner Lower burner Thread suction device Marking lamp 1 (Z) Marking lamp 2 (Z) Marking lamp 3 (Z) Marking lamp 4 (Z) Service Instructions 911-211 - 02.0 - 10/2016...
  • Page 137 Move 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. Service Instructions 911-211 - 02.0 - 10/2016...
  • Page 138 4. Tap the button.  The window for entering the cutting speed opens. 5. Enter the desired value (70 - 500 rpm). 6. Tap the button.  The sewing motor runs at the entered speed. Service Instructions 911-211 - 02.0 - 10/2016...
  • Page 139 Meaning Control events List of the latest errors Log settings Only for Dürkopp Adler Service personnel Log display List of the last log settings Control panel status Status appears in the log display Service Instructions 911-211 - 02.0 - 10/2016...
  • Page 140 Save your seam programs and sequences to a USB key before perform- ing initialization. Initialisierung (Initialize) Steuerung 1. Tap the (Control) option.  The control is completely reset to the factory default settings. Service Instructions 911-211 - 02.0 - 10/2016...
  • Page 141 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. Fig. 111: Updating the control ① (1) - USB port Service Instructions 911-211 - 02.0 - 10/2016...
  • Page 142 To display information on the software version currently used: 1. Tap menu items > Tap on Info  The following information is displayed: • Class • Subclass • Software version • Date of creation of this software version Service Instructions 911-211 - 02.0 - 10/2016...

  • Page 143: Creating Programs With Da-Cad 5000

    Selecting the class The first step is to select the class. Fig. 112: Selecting the class Creating the seam contour The next step is to draw the seam contour. Fig. 113: Creating the seam contour Service Instructions 911-211 - 02.0 - 10/2016...
  • Page 144 Always perform a contour test after creating or editing a contour to ensure that the entire contour lies within the permissible sewing field. Service Instructions 911-211 - 02.0 - 10/2016...
  • Page 145 3. Adjust the program parameters (especially the sewing foot height) ( p. 121). 4. Perform a contour test to check the clamp motion ( p. 113).  Sewing with the program can begin after successful testing/adjustment. Service Instructions 911-211 - 02.0 - 10/2016...
  • Page 146 Creating programs with DA-CAD 5000 Service Instructions 911-211 - 02.0 - 10/2016...

  • Page 147: Maintenance

    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. Service Instructions 911-211 - 02.0 - 10/2016...

  • Page 148: Cleaning The Machine

    • Area under the throat plate (3) • Hook (2) • Area around the needle (1) To clean the machine: 1. Remove any dust and thread remnants using a compressed air gun or a brush. Service Instructions 911-211 - 02.0 - 10/2016...

  • Page 149: Cleaning The Motor Fan Mesh

    Fig. 116: Cleaning the motor fan mesh ① (1) - Motor fan mesh To clean the motor fan mesh. 1. Remove any sewing dust and thread remnants using a compressed air gun. Service Instructions 911-211 - 02.0 - 10/2016...

  • Page 150: Lubricating

    • Flash point: 150 °C You can order the lubricating oil from our sales offices using the following part numbers: Container Part no. 250 ml 9047 000011 9047 000012 9047 000013 9047 000014 Service Instructions 911-211 - 02.0 - 10/2016...

  • Page 151: Lubricating The Machine Head

    1. Check the oil level indicator every day. If the oil level is below the minimum level marking (3): Pour oil through the refill opening (1) but no higher than the maximum lev- el marking (2). Service Instructions 911-211 - 02.0 - 10/2016...

  • Page 152: Lubricating The Hook

    • Turn clockwise: less oil is released Information The released amount of oil does not change until the operating time has run a few minutes. Sew for several minutes before you check the setting again. Service Instructions 911-211 - 02.0 - 10/2016...

  • Page 153: Servicing The Pneumatic System

    2. Turn the pressure controller until the pressure gage (2) indicates the proper setting: • Increase pressure = turn clockwise • Reduce pressure = turn counterclockwise 3. Push the pressure controller (1) down. Service Instructions 911-211 - 02.0 - 10/2016...

  • Page 154: Draining The Water Condensation

    2. Place the collection tray under the drain screw (3). 3. Loosen the drain screw (3) completely. 4. Allow water to drain into the collection tray. 5. Tighten the drain screw (3). 6. Connect the machine to the compressed air supply. Service Instructions 911-211 - 02.0 - 10/2016...

  • Page 155: Cleaning The Filter Element

    6. Wash out the filter tray using benzine. 7. Tighten the filter element (1). 8. Tighten the water separator (2). 9. Tighten the drain screw (3). 10. Connect the machine to the compressed air supply. Service Instructions 911-211 - 02.0 - 10/2016...

  • Page 156: Checking The Toothed Belt

    8.6 Parts list A parts list can be ordered from Dürkopp Adler. Or visit our website for fur- ther information at: www.duerkopp-adler.com Service Instructions 911-211 - 02.0 - 10/2016...

  • Page 157: Decommissioning

    5. Cover the control panel to protect it from soiling. 6. Cover the control to protect it from soiling. 7. Cover the entire machine if possible to protect it from contamination and damage. Service Instructions 911-211 - 02.0 - 10/2016...
  • Page 158 Decommissioning Service Instructions 911-211 - 02.0 - 10/2016...

  • Page 159: Disposal

    When disposing of the machine, be aware that it consists of a range of dif- ferent materials (steel, plastic, electronic components, etc.). Follow the applicable national regulations when disposing of these materials. Service Instructions 911-211 - 02.0 - 10/2016...
  • Page 160 Disposal Service Instructions 911-211 - 02.0 - 10/2016...

  • Page 161: Troubleshooting

    Contact for repairs and issues with the machine: Dürkopp Adler AG Potsdamer Str. 190 33719 Bielefeld, Germany Tel. +49 (0) 180 5 383 756 Fax +49 (0) 521 925 2594 Email: service@duerkopp-adler.com Internet: www.duerkopp-adler.comError and information messages Service Instructions 911-211 - 02.0 - 10/2016...

  • Page 162: Messages Of The Software

    • Too high line voltage • Check the line voltage 2155 X-axis stepper motor overload • Feed system not moving freely • Eliminate sluggishness • Obstacle to feed motion • Remove obstacles/adjust the motion Service Instructions 911-211 - 02.0 - 10/2016...
  • Page 163 • Too high line voltage • Check the line voltage 2355 Stroke position step motor overload • Feed system not moving freely • Eliminate sluggishness • Obstacles to the feed motion • Remove obstacles/adjust the motion Service Instructions 911-211 - 02.0 - 10/2016...
  • Page 164 • Switch off and on the machine 3722 • 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 Service Instructions 911-211 - 02.0 - 10/2016...
  • Page 165 Close the bobbin case retainer 9701 Parallel clamps not lowered • Remove obstacles • Adjust sensors 9900 Incorrect machine parameters Initialize the data 9901 Incorrect sequences Initialize the data 9902 Incorrect program parameters Initialize the data Service Instructions 911-211 - 02.0 - 10/2016...

  • Page 166: Information Messages

    9006 Quick-stop button is active. Release the Quick-stop button 9016 Incorrect barcode ID Change the program 9100 The counter has not reached the Tap the OK button. The counter is specified value. reset. Service Instructions 911-211 - 02.0 - 10/2016...

  • Page 167: Errors In Sewing Process

    Check the assembly of the reel incorrectly stand Thread tensions are too tight Check thread tensions Throat plate, hook or spread Have parts reworked by have been damaged by the qualified specialists needle Service Instructions 911-211 - 02.0 - 10/2016...
  • Page 168 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 material or the thread Service Instructions 911-211 - 02.0 - 10/2016...

  • Page 169: Technical Data

    Table height - Min. 760 or 800 (with 0911 407524) - Max. 900 or 1050 (with 0911 407524) Length/width [mm] 940/1100 1200/1200 Weight (fitted) [kg] Line voltage [V] Mains frequency [Hz] 50/60 Power [W] Service Instructions 911-211 - 02.0 - 10/2016...
  • Page 170 Technical data Service Instructions 911-211 - 02.0 - 10/2016...

  • Page 171: Appendix

    Appendix 13 Appendix 13.1 Wiring diagram Service Instructions 911-211 - 02.0 - 10/2016...
  • Page 172 Appendix Service Instructions 911-211 - 02.0 - 10/2016...
  • Page 173 Appendix Service Instructions 911-211 - 02.0 - 10/2016...
  • Page 174 Appendix Service Instructions 911-211 - 02.0 - 10/2016...
  • Page 175 Appendix Service Instructions 911-211 - 02.0 - 10/2016...
  • Page 176 Appendix Service Instructions 911-211 - 02.0 - 10/2016...
  • Page 177 Appendix Service Instructions 911-211 - 02.0 - 10/2016...
  • Page 178 Appendix Service Instructions 911-211 - 02.0 - 10/2016...
  • Page 179 Appendix Service Instructions 911-211 - 02.0 - 10/2016...
  • Page 180 Appendix Service Instructions 911-211 - 02.0 - 10/2016...
  • Page 181 Appendix Service Instructions 911-211 - 02.0 - 10/2016...
  • Page 182 Appendix Service Instructions 911-211 - 02.0 - 10/2016...
  • Page 183 Appendix Service Instructions 911-211 - 02.0 - 10/2016...
  • Page 184 Appendix Service Instructions 911-211 - 02.0 - 10/2016...
  • Page 185 Appendix Service Instructions 911-211 - 02.0 - 10/2016...
  • Page 186 Appendix Service Instructions 911-211 - 02.0 - 10/2016...
  • Page 187 Appendix Service Instructions 911-211 - 02.0 - 10/2016...
  • Page 188 Appendix & " & & Service Instructions 911-211 - 02.0 - 10/2016...
  • Page 189 Appendix Service Instructions 911-211 - 02.0 - 10/2016...
  • Page 190 Appendix Service Instructions 911-211 - 02.0 - 10/2016...
  • Page 191 Appendix Service Instructions 911-211 - 02.0 - 10/2016...
  • Page 192 Appendix Service Instructions 911-211 - 02.0 - 10/2016...
  • Page 193 Appendix & & & Service Instructions 911-211 - 02.0 - 10/2016...
  • Page 194 Appendix # " ! " ! " ! " ! " ! Service Instructions 911-211 - 02.0 - 10/2016...
  • Page 195 Appendix Service Instructions 911-211 - 02.0 - 10/2016...

  • Page 196: Wiring Diagram - Remaining Thread Monitor

    Appendix 13.2 Wiring diagram - remaining thread monitor Service Instructions 911-211 - 02.0 - 10/2016...

  • Page 197: Pneumatic Diagram

    Appendix 13.3 Pneumatic diagram Service Instructions 911-211 - 02.0 - 10/2016...

  • Page 198: Pneumatic Diagram For Machines With Remaining Thread Monitor

    Appendix 13.4 Pneumatic diagram for machines with remaining thread monitor Service Instructions 911-211 - 02.0 - 10/2016...
  • Page 200 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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