DURKOPP ADLER 991-210-10 Series Service Instructions Manual
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DURKOPP ADLER 991-210-10 Series Service Instructions Manual

DURKOPP ADLER 991-210-10 Series Service Instructions Manual

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911-210-10
Service Instructions

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Summary of Contents for DURKOPP ADLER 991-210-10 Series

  • Page 1 911-210-10 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 2020...

  • Page 3: Table Of Contents

    Table of Contents About these instructions ............5 For whom are these instructions intended?........5 Representation conventions – symbols and characters ....5 Other documents ................7 Liability..................7 Safety ................... 9 Basic safety instructions ............... 9 Signal words and symbols used in warnings ......10 Working basis ................
  • Page 4 Table of Contents Adjusting the needle thread tension........48 10.1 Adjusting the needle thread regulator......... 48 10.2 Adjusting the thread tensioning spring ........49 10.3 Adjusting the thread tension plate ..........50 10.4 Calibrating the thread tension plate ..........51 Short thread cutter (KFA)............
  • Page 5 Table of Contents 16.8.2 Continuing a seam after thread breaking ........87 16.9 Resetting the counter ..............88 16.10 Seam programs and seam sequences ........89 16.10.1 Creating a new seam program ..........89 16.10.2 Performing a contour test ............92 16.10.3 Editing a seam program............
  • Page 6 Table of Contents Technical data................. 145 21.1 Data and characteristic values ..........145 21.2 Requirements for fault-free operation ........146 Service Instructions 911-210-10 - 00.0 - 06/2020...

  • Page 7: About These Instructions

    About these instructions About these instructions These instructions have been prepared with utmost care. They contain information and notes intended to ensure long-term and reliable operation. Should you notice any discrepancies or if you have improvement requests, then we would be glad to receive your feedback through Customer Service (...
  • Page 8 About these instructions Steps to be performed when operating the machine (sewing and equipping) Steps to be performed for service, maintenance, and installation Steps to be performed via the software control panel The individual steps are numbered: First step Second step The steps must always be followed in the specified order.

  • Page 9: Other Documents

    About these instructions 1.3 Other documents The machine includes components from other manufacturers. Each man- ufacturer has performed a hazard assessment for these purchased parts and confirmed their design compliance with applicable European and na- tional regulations. The proper use of the built-in components is described in the corresponding manufacturer's instructions.
  • Page 10 About these instructions Service Instructions 911-210-10 - 00.0 - 06/2020...

  • Page 11: Safety

    Safety Safety This chapter contains basic information for your safety. Read the instruc- tions carefully before setting up or operating the machine. Failure to do so can result in serious injury and property damage. 2.1 Basic safety instructions The machine may only be used as described in these instructions. These instructions must be available at the machine's location at all times.

  • Page 12: Signal Words And Symbols Used In Warnings

    Safety Check the machine during operating for any externally visible damage. Operation Stop working if you notice any changes to the machine. Report any chang- es to your supervisor. Do not use a damaged machine any further. Safety equipment should not be disassembled or deactivated. If it is essen- Safety equipment tial to disassemble or deactivate safety equipment for a repair operation, it...
  • Page 13 Safety Symbol Type of danger Puncture Crushing Environmental damage Examples of the layout of warnings in the text: Examples DANGER 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 will result in serious injury or even death if ignored.
  • Page 14 Safety CAUTION 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 environmental damage if ignored. NOTICE Type and source of danger! Consequences of non-compliance.

  • Page 15: Working Basis

    Working basis Working basis 3.1 Order of the adjustments Order The setting positions for the machine are interdependent. Always comply with the order of individual adjustment steps as specified. It is absolutely essential that you follow all notices regarding prerequisites and subsequent settings that are marked with in the margin.

  • Page 16: Disassembling And Assembling Covers

    Working basis 3.3 Disassembling and assembling covers WARNING Risk of injury from moving parts! Crushing possible. Switch off the machine before removing or re-assembling covers. For many types of adjustment work, you will have to remove the machine covers first in order to access the components. This chapter describes how to remove and then assemble the individual covers again.
  • Page 17 Working basis Fig. 1: Swiveling the machine head up and down ① ② ③ (1) - Head cover (3) - Locking lever (2) - Latch Swiveling up the machine head Important The transport carriage must be at the rear. To swivel up the machine head: 1.

  • Page 18: Disassembling And Assembling The Arm Cover

    Working basis 3.3.2 Disassembling and assembling the arm cover Fig. 2: Disassembling and assembling the arm cover ① ⑤ ④ ② ③ (1) - Motor cover (4) - Arm cover (2) - Screws (5) - Hand crank (3) - Countersunk screw Disassembling the arm cover To disassemble the arm cover: 1.

  • Page 19: Disassembling And Assembling The Head Cover

    Working basis 3.3.3 Disassembling and assembling the head cover Fig. 3: Disassembling and assembling the head cover ① ② (1) - Screws (2) - Head cover Disassembling the head cover To disassemble the head cover: 1. Loosen the screws (1). 2.

  • Page 20: Removing And Placing The Rear Cover

    Working basis 3.3.4 Removing and placing the rear cover Fig. 4: Removing and placing the rear cover ① ② (1) - Screws (2) - Rear cover Removing the rear cover To remove the rear cover: 1. Loosen the screws (1). 2.

  • Page 21: Removing And Placing The Toothed Belt Cover

    Working basis 3.3.5 Removing and placing the toothed belt cover Fig. 5: Removing and placing the toothed belt cover ① ② (1) - Screws (2) - Toothed belt cover Removing the toothed belt cover To remove the toothed belt cover: 1.

  • Page 22: Opening And Closing The Hook Cover

    Working basis 3.3.6 Opening and closing the hook cover Opening the hook cover To open the hook cover: 1. Switch on the machine and reference it. 2. Remove the sewing material holder. 3. Press the Einfädelmodus (Threading mode) button.  The hook cover swivels to the side. Closing the hook cover To close the hook cover: 1.

  • Page 23: Aligning The Machine Head

    Working basis 3.5 Aligning the machine head Fig. 7: Aligning the machine head (1) ③ ① ② (1) - Base plate (3) - Flat material (2) - Tabletop Proper setting The upper side of the base plate (1) is level with the cutout in the tabletop (2). Height X of the transport system is identical on the left and the right both at the rear and the front position of the carriage.
  • Page 24 Working basis Fig. 8: Aligning the machine head (2) Carriage at rear position Carriage at front position 5. Check the position of the machine head again. • Front • Carriage at rear position • Carriage at front position Service Instructions 911-210-10 - 00.0 - 06/2020...
  • Page 25 Working basis Fig. 9: Aligning the machine head (3) ④ ⑤ ⑥ ④ ⑤ ⑦ (4) - Screws (6) - Screws (5) - Nuts (7) - Block 6. Loosen the nuts (5). 7. Swivel down the machine head and lock it in place. 8.
  • Page 26 Working basis Fig. 10: Aligning the machine head (4) ⑨ ⑧ (8) - Screw on the right (9) - Threaded pin on the right 12. Loosen the screws on the left (not shown) and on the right (8). 13. Use the threaded pins on the left (not shown) and on the right (9) to adjust the height of the machine head at the rear: •...

  • Page 27: Locking The Machine In Place

    Working basis 3.6 Locking the machine in place For some adjustments, the machine must be locked in place. To do this, the locking peg from the accessories is inserted into a slot on the arm shaft crank, blocking the arm shaft. Fig.

  • Page 28: Putting The Machine Into Position

    Working basis Locking the machine in place To lock the machine in place: 1. Insert the locking peg (2) with the appropriate end into the slot (1). Removing the lock To remove the lock: 1. Pull the locking peg (2) out of the slot (1). 3.7 Putting the machine into position For some settings, the machine must be put into a certain position, using the hand crank on the arm cover.

  • Page 29: Positioning The Arm Shaft Crank

    Positioning the arm shaft crank Positioning the arm shaft crank WARNING Risk of injury from moving parts! Crushing possible. Switch off the machine before you check and set the position of the arm shaft crank. Fig. 14: Positioning the arm shaft crank ①...

  • Page 30: Positioning The Toothed Belt Wheels

    Positioning the toothed belt wheels Positioning the toothed belt wheels WARNING Risk of injury from moving parts! Crushing possible. Switch off the machine before you check and set the toothed belt wheels. Proper setting The two toothed belt wheels must be positioned relative to each other such that the toothed belt can run correctly.

  • Page 31: Adjusting The Lower Toothed Belt Wheel

    Positioning the toothed belt wheels 4. Turn the upper toothed belt wheel (3) such that the threaded pins (1) are seated flush on the flat (2) of the arm shaft. 5. Tighten the threaded pins (1). 6. Use the screwdriver to push the toothed belt (4) back again. 5.2 Adjusting the lower toothed belt wheel Fig.

  • Page 32: Aligning The Needle Bar Linkage

    Aligning the needle bar linkage Aligning the needle bar linkage WARNING Risk of injury from moving parts! Crushing possible. Switch off the machine before aligning the needle bar linkage sideways. Fig. 17: Aligning the needle bar linkage ① ② ③ (1) - Threaded pin (3) - Needle hole (2) - Needle bar linkage...

  • Page 33: Position Of The Hook And Needle

    Position of the hook and needle Position of the hook and needle WARNING Risk of injury from sharp parts! Puncture possible. Switch off the machine before adjusting the hook settings. WARNING Risk of injury from moving parts! Crushing possible. Switch off the machine before adjusting the hook settings.
  • Page 34 Position of the hook and needle Order First, check the following settings: • Aligning the needle bar linkage ( p. 30) Proper setting The machine is locked in place at position 1 ( p. 25).  The hook tip (3) is precisely at the center of the needle (1). The looping stroke is precisely 2 mm.

  • Page 35: Adjusting The Needle Bar Height

    Position of the hook and needle 7.2 Adjusting the needle bar height Order First, check the following settings: • Adjusting the looping stroke position ( p. 31) Proper setting The machine is locked in place at position 1 ( p. 25). ...

  • Page 36: Adjusting The Hook Side Clearance

    Position of the hook and needle 7.3 Adjusting the hook side clearance NOTICE Property damage may occur! There is a risk of machine damage, needle breakage or damage to the thread if the distance between needle groove and hook tip is incorrect.

  • Page 37: Adjusting The Needle Guard

    Position of the hook and needle To adjust the hook side clearance: 1. Lock the machine in place at position 1 ( p. 25). 2. Swivel up the machine head ( p. 14). 3. Loosen the screws (2). 4. Loosen the threaded pins (1). 5.
  • Page 38 Position of the hook and needle Fig. 22: Adjusting the needle guard ③ ① ② (1) - Needle guard (3) - Needle (2) - Screw To adjust the needle guard: 1. Press down and turn the hand crank and check how far the needle guard (1) pushes the needle (3) away.

  • Page 39: Adjusting The Needle Guide

    Position of the hook and needle 7.5 Adjusting the needle guide Proper setting Machine is locked in place at position 1 ( p. 25).  The needle guard pushes the needle just enough away so that it cannot be touched by the hook tip. Fig.

  • Page 40: Adjusting The Bobbin Case Lifter

    Adjusting the bobbin case lifter Adjusting the bobbin case lifter WARNING Risk of injury from moving parts! Crushing possible. Switch off the machine before adjusting the settings on the bobbin case lifter. Fig. 25: Adjusting the bobbin case lifter ① ④...

  • Page 41: Adjusting The Lifting Gap

    Adjusting the bobbin case lifter 8.1 Adjusting the lifting gap Order Always check the width of the lifting gap after making changes to the needle thread size. The correct width of the lifting gap depends on the thickness of the needle thread. Proper setting The needle thread slides through unobstructed between the nose of the bobbin case and the bobbin case support.

  • Page 42: Adjusting The Timing For Opening

    Adjusting the bobbin case lifter 8.2 Adjusting the timing for opening Fig. 27: Adjusting the timing for opening ① ② (1) - Plug (2) - Threaded pin Proper setting The bobbin case lifter starts to open exactly at the point when the hook tip is located below the bobbin case lifter after the loop is taken up.

  • Page 43: Sewing Foot Lift

    Sewing foot lift Sewing foot lift WARNING Risk of injury from sharp and moving parts! Puncture or crushing possible. Switch off the machine before adjusting the settings of the sewing foot lift. 9.1 Adjusting the stroke position drive Fig. 28: Adjusting the stroke position drive ①...

  • Page 44: Adjusting The Light Barrier

    Sewing foot lift 9.2 Adjusting the light barrier Fig. 29: Adjusting the light barrier ① ④ ② ③ (1) - Mounting plate (3) - Screw (2) - Light barrier (4) - Lever Proper setting The light barrier with its mounting plate must be installed so that the toothed rack triggers it before reaching the upper stop.

  • Page 45: Adjusting The Left Stop Screw

    Sewing foot lift 9. Push the lever (4) up and monitor the display.  It will show either +103 or -103. 10. Check that the toothed rack still has about 0.5 mm clearance from the stop. 11. If necessary, set the light barrier again using the mounting plate. 9.3 Adjusting the left stop screw Proper setting The left stop screw (3) of the lifting gear must be set so that the lever (1)

  • Page 46: Adjusting The Sewing Foot Stroke Relative To The Needle Bar Stroke

    Sewing foot lift 9.4 Adjusting the sewing foot stroke relative to the needle bar stroke Fig. 31: Adjusting the sewing foot stroke relative to the needle bar stroke ① ⑥ ⑤ ④ ② ③ (1) - Lever (4) - Sewing foot stroke (2) - Lifting gear (5) - Stop screw (3) - Eccentric...

  • Page 47: Adjusting The Sewing Foot Height

    Sewing foot lift 6. Turn the machine head to the looping stroke position.  The lever (1) must make a movement. 7. Loosen both threaded pins on the eccentric (3). 8. Rotate the eccentric (3) on the arm shaft. 9. Tighten both threaded pins on the eccentric (3). 10.

  • Page 48: Adjusting The Reference Light Barrier Sewing Axis

    Sewing foot lift 9. Turn the pivot shaft so that the distance between throat plate and sewing foot is 1 mm. 10. Tighten the screw (3). 11. Turn the sewing foot to top dead center.  The distance between the throat plate and sewing foot must be 5 mm.
  • Page 49 Sewing foot lift 7. Loosen the threaded pin (2). 8. Rotate the take-up lever disk (1) on the arm shaft.  The switch S100 then switches. 9. Tighten the threaded pin (2). 10. Remove the lock ( p. 25). 11. Switch off and on the machine again. 12.

  • Page 50: Adjusting The Needle Thread Tension

    Adjusting the needle thread tension 10 Adjusting the needle thread tension 10.1 Adjusting the needle thread regulator The needle thread regulator determines the tension applied to guide the needle thread around the hook. The required tension depends on the thickness of the sewing material, the thread strength, and the stitch length. Fig.

  • Page 51: Adjusting The Thread Tensioning Spring

    Adjusting the needle thread tension 10.2 Adjusting the thread tensioning spring The thread tensioning spring holds the needle thread under tension from the top dead center of the thread lever up to the point when the needle eye plunges into the sewing material. Proper setting Initial position: The thread tensioning spring does not contact the stop until the needle eye has plunged into the sewing material.

  • Page 52: Adjusting The Thread Tension Plate

    Adjusting the needle thread tension 10.3 Adjusting the thread tension plate Fig. 36: Adjusting the thread tension plate ① ② ③ ④ (1) - Tension disks (3) - Nut (2) - Washer (4) - Screw To adjust the thread tension plate: 1.

  • Page 53: Calibrating The Thread Tension Plate

    Adjusting the needle thread tension 18. Press ESC and check that the tension disks (1) open easily. 19. Press Kalibrierung 1 (Calibration 1) and check the closure of the tension disks. 20. Repeat the procedure for the 2 thread tension. 10.4 Calibrating the thread tension plate Fig.

  • Page 54: Short Thread Cutter (Kfa)

    Short thread cutter (KFA) 11 Short thread cutter (KFA) WARNING Risk of injury from sharp and moving parts! Puncture or crushing possible. Switch off the machine before adjusting the short thread cutter settings. NOTICE Property damage may occur! Risk of breakage. Never operate the machine without the thread-pulling knife.

  • Page 55: Adjusting Thread-Pulling Knife And Control Cam

    Short thread cutter (KFA) 11.1 Adjusting thread-pulling knife and control cam Fig. 38: Adjusting thread-pulling knife and control cam (1) ① ② ③ (1) - Thread-pulling knife (3) - Knife carrier (2) - Counter blade Thread-pulling knife height The height of the thread-pulling knife is set at the factory using washers underneath the knife carrier (3).

  • Page 56: Adjusting The Locking Latch

    Short thread cutter (KFA) Control cam Fig. 39: Adjusting thread-pulling knife and control cam (2) ④ ⑤ (4) - Control cam (5) - Set collar Important The control cam (5) must make contact with the stop on the set collar (4). 11.2 Adjusting the locking latch Fig.

  • Page 57: Adjusting The Thread-Pulling Knife

    Short thread cutter (KFA) Proper setting Press down and turn the hand crank until the roller (2) is at the highest point of the control cam (3). Press the roller (2) against the control cam (3).  The locking latch (1) can be swung out without clamping, and the distance between the locking latch (1) and locking pin (6) is no greater than 0.1 mm.

  • Page 58: Adjusting The Counter Blade

    Short thread cutter (KFA) To adjust the thread-pulling knife: 1. Loosen the screws on the set collar (5). 2. Slide the set collar (5) up to the hook bearing. 3. Tighten the screws on the set collar (5). 4. Loosen the screws on the control cam (6). 5.
  • Page 59 Short thread cutter (KFA) Adjusting the cutting pressure The shape of the thread-pulling knife automatically creates the required cutting pressure as soon as both cutting edges are on top of one another. Fig. 43: Adjusting the cutting pressure ④ ① ③...

  • Page 60: Adjusting The Cutoff Position

    Short thread cutter (KFA) 11.5 Adjusting the cutoff position Fig. 44: Adjusting the cutoff position ① ② (1) - Control cam (2) - Threaded pins Proper setting The default is that the cutoff position is “thread lever at top dead center”. When the machine is at the position “thread lever at top dead center”, the control cam (1) is at its highest point.

  • Page 61: Changing The Presser Bar

    Changing the presser bar 12 Changing the presser bar 12.1 Disassembling the presser bar Fig. 45: Disassembling the presser bar (1) ① ② ③ ④ ⑤ (1) - Bearing with gear wheel (4) - Screws (2) - Threaded pins (5) - Screw (3) - Drive To disassemble the presser bar: 1.
  • Page 62 Changing the presser bar Fig. 46: Disassembling the presser bar (2) ⑥ ⑩ ⑦ ⑧ ⑨ (6) - Block (9) - Presser bar (7) - Screw (10) - Sleeve (8) - Clip 6. Position the clip (8) so that the screw (7) is accessible. 7.

  • Page 63: Assembling The Presser Bar

    Changing the presser bar 12.2 Assembling the presser bar Fig. 47: Assembling the presser bar (1) ① ⑤ ② ③ ④ (1) - Block (4) - Presser bar (2) - Screw (5) - Sleeve (3) - Clip To assemble the presser bar: 1.
  • Page 64 Changing the presser bar Fig. 48: Assembling the presser bar (2) ⑥ ⑦ ⑧ ⑨ ⑩ (6) - Bearing with gear wheel (9) - Screws (7) - Threaded pins (10) - Screw (8) - Drive 5. Tighten the screw (10). 6.

  • Page 65: Checking The Machine Zero Point

    Checking the machine zero point 13 Checking the machine zero point The machine zero point is factory-set to the correct value. Fig. 49: Checking the machine zero point ① ② ③ (1) - Clamp with test bores (3) - Test bore (2) - Center point bore Gage required: Clamp with test bores.

  • Page 66: Changing The Drives

    Changing the drives 14 Changing the drives WARNING Risk of injury from sharp and moving parts! Puncture or crushing possible. Switch off the machine before changing the drives. 14.1 Changing the sewing motor 14.1.1 Disassembling the sewing motor To disassemble the sewing motor: 1.

  • Page 67: Assembling The Sewing Motor

    Changing the drives 7. Remove the toothed belt wheel (4). To do so, loosen the screw on the toothed belt wheel. 8. Loosen the screws (3). 9. Remove the motor from the plate (2). 14.1.2 Assembling the sewing motor Fig. 51: Assembling the sewing motor ⑤...

  • Page 68: Changing The X Drive

    Changing the drives 14.2 Changing the X drive Fig. 52: Changing the X drive ① ⑤ ② ② ③ ④ (1) - Plug (4) - Toothed belt (2) - Screws (5) - Screw (3) - Motor with flange Disassembling the drive To disassemble the drive: 1.

  • Page 69: Changing The Y Drive

    Changing the drives 14.3 Changing the Y drive Fig. 53: Changing the Y drive ① ② ③ ⑦ ④ ⑤ ⑥ (1) - Plug (5) - Toothed belt (2) - Screws (6) - Motor (3) - Screw (7) - Flange (4) - Equipotential bonding Disassembling the drive To disassemble the drive:...

  • Page 70: Checking The Play Between Toothed Rack And Gear Wheel

    Checking the play between toothed rack and gear wheel 15 Checking the play between toothed rack and gear wheel The play between the toothed rack and the gear wheel must be checked on both sides of the machine. Because the structure is similar on both sides, testing is described here for one side only as an example.

  • Page 71: Programming

    Programming 16 Programming Fig. 55: Programming ① (1) - Control panel OP7000 The control is operated via the control panel OP7000 (1) located on the right next to the machine head. The screen is a touchscreen, i.e. the buttons are displayed on the screen rather than provided as physical buttons.

  • Page 72: Structure Of The Software

    Programming 16.1 Structure of the software You can create and manage seam programs and sequences via software. During sewing, these programs are called up and processed stitch by stitch. Information Seam program: A seam program consists of a seam contour with parameters defining the individual contour sections.

  • Page 73: Starting The Software

    Programming Menu items in popup menus Menu item Function Sub-items Sub-items Described on  p. 81 Extras Display options: Vollbild ein/aus full-screen and zoom (Full screen on / off)  p. 81 Zoom ein/aus Technician menu: (Zoom on / off) Adjustments, system ...
  • Page 74 Programming Information Both functions can also be selected later from within the program via the menu items Extras > Service (See chapters Testing the functions of the machine  p. 115) and Changing the language ( p. 113).) If you do not press any buttons, the software automatically switches to the start screen after a few seconds.
  • Page 75 Programming • Program bar (4) The seam programs of the seam sequence currently open are displayed in this line. The program currently being executed is highlighted in black. You can use the arrow buttons (6) at the right side of the bar to navigate along the bar and display any additional programs that do not fit on the bar.

  • Page 76: General Operation Of The Software

    Programming Information You can use the buttons Speed, Thread tension and Stitch length to access the sewing parameters directly ( p. 95). • Button for Repair mode (9) The topmost button at the right side is used for switching the repair mode on and off.

  • Page 77: Closing Windows

    Programming 16.4.2 Closing windows A number of different buttons can be used for closing the currently open window. Button Meaning At the upper right in the title bar of all windows:  The program jumps back by one navigation level. In windows with data entry or selection fields: ...

  • Page 78: Scrolling The Display

    Programming 16.4.4 Scrolling the display Fig. 61: Scrolling the display ① (1) - Scrollbar A scrollbar (1) is displayed on the right when a displayed image is larger than the screen height. To scroll the display: 1. Drag the scrollbar (1) up or down. 16.4.5 Selecting options from a list When selecting options, a distinction is made between round radio buttons and square check boxes.
  • Page 79 Programming To select options using radio buttons: 1. Press the desired option.  The selected option (1) is marked with a dot. Selection with check boxes Fig. 63: Selection with check boxes ① (1) - Check box: Selected elements Square check boxes allow for the selection of multiple entries. To select options using check boxes: 1.

  • Page 80: Using File Filters

    Programming 16.4.6 Using file filters Fig. 64: File filter When opening, copying or deleting seam programs a list of all available files is displayed. You can use the filter functions to make the list more manageable: To use file filters: 1.

  • Page 81: Entering Text

    Programming 16.4.7 Entering text A text entry window is displayed when text needs to be entered, e.g. for the name of a seam program. Fig. 65: Entering text ① ② ⑤ ④ ③ (1) - Input line (4) - DEL: Delete a character (2) - Keyboard (5) - Aa: Switching between uppercase/ (3) - OK (CR): Adopt the entered text...

  • Page 82: Entering Parameter Values

    Programming 16.4.8 Entering parameter values A numeric entry window opens when numeric values for program or machine parameters need to be entered. Fig. 66: Entering parameter values ① ② ③ ⑥ ④ ⑤ (1) - Title bar (4) - Value range (2) - Status bar (5) - Input field (3) - Symbol...

  • Page 83: Switching The Full-Screen Display On And Off

    Programming 16.4.9 Switching the full-screen display on and off In order to see the seam contour in more detail you can switch the main window (1) to occupy the full screen and hide the buttons (2) on the right side of the start screen. Fig.

  • Page 84: Opening A Seam Program Or Seam Sequence For Sewing

    Programming 16.5 Opening a seam program or seam sequence for sewing To open a seam program or seam sequence for sewing: Datei (File) Öffnen (Open) 1. Press the menu items >  The file selection screen is displayed. All existing seam programs and seam sequences are displayed. Information Dateifilter (File Filter) You can use the...

  • Page 85: Briefly Sewing With Modified Values

    Programming 16.6 Briefly sewing with modified values If you wish to briefly sew with a special material or use a particular thread strength with different values, without changing the seam program, you can use the Korrektur (Correction) menu item to temporarily change the values for thread tension and speed.

  • Page 86: Sewing With A Modified Speed

    Programming 16.6.2 Sewing with a modified speed To sew with a modified speed: Korrektur (Correction) 1. Press the menu items > Nähdrehzahl (Speed)  The window for changing the thread tension appears: Fig. 71: Sewing with a modified speed 2. Enter the desired speed. 3.

  • Page 87: Changing The Bobbin

    Programming 16.7.1 Changing the bobbin Fig. 72: Changing the bobbin To change the bobbin: 1. Press the Spulenwechsel (Bobbin change) button. 2. Change the bobbin ( p. 84). 3. Use the Vor (Forwards) Zurück (Back) buttons to move to the point where sewing is to continue. 4.

  • Page 88: Continuing A Seam After An Error

    Programming 16.8 Continuing a seam after an error 16.8.1 Continuing a seam in Repair mode after an error In Repair mode you can move to any desired point on the contour, e.g. in order to continue the seam program from this position after an error has occurred.

  • Page 89: Continuing A Seam After Thread Breaking

    Programming 16.8.2 Continuing a seam after thread breaking When the machine was set up, the needle thread monitor mode that is supposed to be active was selected in the machine parameters (MP 3 ( p. 109)). In the event of an error, the machine will undo a certain number of preset stitches and stop.

  • Page 90: Resetting The Counter

    Programming Checking or changing the bobbin To change or check the bobbin: 1. Press the Spulenwechsel (Bobbin change) button.  The display shows a prompt asking whether you wish to reset the bobbin counter. 2. Press the JA (YES) button if you wish to change the bobbin. ...

  • Page 91: Seam Programs And Seam Sequences

    Programming 16.10 Seam programs and seam sequences 16.10.1 Creating a new seam program New seam programs are created using a Teach-In procedure. Individual seam paths with specific sewing parameters are defined via the control panel in order to do this. To create a new seam program: Datei (File) Neu (New)
  • Page 92 Programming 3. Press the OK (4) button.  The desired starting point is adopted and marked with a green / blue dot. Selecting the line type 4. Use the line selection buttons (8) to select the type of line to be defined: •...
  • Page 93 Programming Button Meaning Thread tension Stroke height Thread cutting Drawing a path 7. Use the arrow buttons to move the cursor to the end point of the desired path. Information Alternatively, you can press an arrow button once in order to define the di- rection and then continue moving in this direction by pressing the pedal.

  • Page 94: Performing A Contour Test

    Programming Saving a seam program After you have defined all the seam paths, you can save the seam program and specify a name for the program. 1. Press the Speich...(Save...) button.  The window for entering the name of the seam program opens. 2.

  • Page 95: Editing A Seam Program

    Programming Fig. 77: Performing a contour test 2. Move along the contour stitch by stitch using the Vor (Forwards) and Zurück (Back) buttons or the pedal. 3. Check that all points lie within the sewing field. 16.10.3 Editing a seam program You can change the contour and the sewing parameters of existing seam programs.
  • Page 96 Programming Fig. 78: Changing the contour of a seam program (1) ① ② (1) - Cursor (2) - Scale: First to last stitch 2. Use the arrow buttons to move the cursor (1) to the position on the contour that is to be changed. Information You can also use the slider control on the scale (2) to select the stitching area you wish to change:...
  • Page 97 Programming Fig. 80: Changing the contour of a seam program (3) 6. Select the desired technology operation(s) for the new seam path ( p. 76). 7. Confirm the selection with OK.  You are returned to the detail window with the modified contour. 8.
  • Page 98 Programming Fig. 81: Changing seam program parameters 2. Press the desired parameter group.  The individual parameters of this group are displayed. 3. Press the desired parameter.  The window for modifying the parameter value opens. 4. Set the parameter to the desired value ( p. 80). Service Instructions 911-210-10 - 00.0 - 06/2020...
  • Page 99 Programming There are 8 program parameter groups: Symbol Parameter group PP1 - Configuration General settings PP2 - Load mode Load mode and position PP3 - Deposit mode Deposit 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...
  • Page 100 Programming Symbol Meaning Marking lamps Up to 4 marking lamps for easier alignment of the sewing material can be controlled (the additional equipment must be activated) Reversal mode The following options can be set: • Not activated: The needle remains at the Stop position •...
  • Page 101 Programming Symbol Meaning 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. PP3 - Deposit mode Symbol Meaning Deposit mode The following options can be set: •...
  • Page 102 Programming PP4 - Soft start Symbol Meaning Soft-start stitch count (min. = 0.. max. = 10; Def. 5) Soft-start speed (min. = 100 .. max. = 2000; Def. 300 rpm) PP5 - Needle thread monitor (min. = 0 .. max. = 99; Def. 5) Only active if activated in the machine parameters.

  • Page 103: Creating A New Seam Sequence

    Programming PP8 - Scaling. Symbol Meaning X scaling (min. = 80… max. = 120; Def. = 100 %) 100% corresponds to the original size. Y scaling (min. = 80… max. = 120; Def. = 100 %) X scaling origin (min. = -150.0… max. = 150.0; Def. = 0.0 mm) Y scaling origin (min.

  • Page 104: Editing A Seam Sequence

    Programming The existing seam programs are displayed at the right side of the screen. The field Sequenz (Sequence) field on the left shows the seam programs that have been transferred to the seam sequence. 2. Press the desired seam program. ...

  • Page 105: Saving A Seam Program Or Seam Sequence Under A Different Name

    Programming Fig. 83: Editing a seam sequence 3. Use the buttons Einfügen (Insert) and Löschen (Delete) to add programs to the seam sequence or remove programs from the seam sequence. 16.10.6 Saving a seam program or seam sequence under a different name You can also save existing seam programs or seam sequences under a different name.

  • Page 106: Copying A Seam Program Or Seam Sequence

    Programming 4. Enter the desired name and adopt the change by pressing (CR) ( p. 79).  The seam program or seam sequence is now available under this name for sewing, editing or copying. 16.10.7 Copying a seam program or seam sequence You can also copy seam programs or seam sequences from a USB key to the control or from the control to a USB key.

  • Page 107: Deleting A Seam Program Or Seam Sequence

    Programming 4. Press the Datei kopieren (Copy File) button.  The selected file is copied to the USB key or the control. 16.10.8 Deleting a seam program or seam sequence Seam programs or seam sequences that are no longer required can be deleted from the control.

  • Page 108: Editing Machine Parameters

    Programming 16.11 Editing machine parameters You use the machine parameters to define the basic machine settings. These basic settings apply to all programs. To edit the machine parameters: 1. Press the menu items Bearbeiten (Edit) > Maschinen- parameter (Machine parameters) ...
  • Page 109 Programming Overview of the individual machine parameters MP1 - Configuration Symbol Meaning Needle cooling The following options can be set: • Without: No needle cooler activated. • Air cooling (Def.): The needle is cooled with air while sewing the seam •...
  • Page 110 Programming Symbol Meaning Pedal mode The following options are available: • Mode 1: The current position of the pedal is evaluated • Mode 2 (Def.): The pedal must be returned to the initial position after every actuation before a new actuation is recognized •...
  • Page 111 Programming MP2 - Limit values Symbol Meaning Max. speed (min. = 500 .. max. = 2700; Def. 2700 rpm) All sewing programs are limited to this maximum speed Max. run-empty speed (min. = 10 .. max. = 100; Def. 100 %) Limits all clamp movements between the seams to this value Feed starting angle (min.
  • Page 112 Programming Symbol Meaning 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 MP4 - Thread cutting Symbol Meaning Cutting speed...
  • Page 113 Programming MP6 - Counters Symbol Meaning Counter type The following options are available: • Increment counter (Def.): The counter is incremented after each sewn program • Decrement counter: The counter is decremented after each sewn program • Increment seam sequence counter: The counter is incremented after each seam sequence sewn •...

  • Page 114: Checking And Changing The Technical Settings

    Programming 16.12 Checking and changing the technical settings The technical settings are made via the menu item Extras > Service Fig. 89: Checking and changing the technical settings Important A password must always be entered in order to access the additional Extras Service menu items in...

  • Page 115: Changing The Language

    Programming Defining the password protected areas To define the password protected areas: Extras Service Einstellungen 1. Press the menu items > > (Settings)  The Einstellungen (Settings) window appears. Operator Passwort (Password) 2. Press the option.  In the next window the Aktivieren/De-aktivieren (Activate/Deactivate) option indicates the type of...

  • Page 116: Setting The Brightness

    Programming 16.12.4 Setting the brightness To set the brightness: Extras Service Einstellungen 1. In the menu item > > (Settings) Bedienfeld-Einstellungen press the (Control panel settings) option. Kontrast (Contrast) 2. In the following window press the Helligkeit (Brightness) option.  A window with slider controls is displayed. 3.

  • Page 117: Testing The Functions Of The Machine

    Programming 16.13 Testing the functions of the machine You can use the Extras > Service > Multitest (Multi test) menu item to check the inputs and outputs, test the sewing motor and set the stroke position. Fig. 90: Testing the functions of the machine Information Transportklammer (Transport clamp) function...
  • Page 118 Programming Fig. 91: Testing inputs and outputs ① ② (1) - Area for input elements (2) - Area for output elements The input elements are listed and selected at the left side (1) and the output elements at the right side (2). ausgewählt: (selected:) 2.

  • Page 119: Adjusting The Stroke Position

    Programming Output elements Meaning Foot mode Hook cover Needle cooling on Right clamp Left clamp Stitch position optimization Threading switch lamp on Oil level indicator warning light on Marking lamp 1 (Z) Marking lamp 2 (Z) Marking lamp 3 (Z) Marking lamp 4 (Z) 16.13.2 Adjusting the stroke position WARNING...

  • Page 120: Testing The Sewing Motor

    Programming Symbol Meaning Go to position Adjust the sewing foot height Switch off the power to the drives Manually check the freedom of motion of the sewing foot rod 2. Press the desired symbol and execute the function. 16.13.3 Testing the sewing motor WARNING Risk of injury from sharp and moving parts! Puncture or crushing possible.

  • Page 121: Calling Up Log Displays And Error Lists

    Programming 3. Enter the desired value (300 - 2000 rpm). 4. Press the button.  The window for entering the cutting speed opens. 5. Enter the desired value (70 - 500 rpm). 6. Press the button.  The sewing motor runs at the entered speed. 7.

  • Page 122: Initializing The Control And Performing Updates

    Programming Symbol Meaning Control unit events List of the latest errors Log configuration Only for Dürkopp Adler Service personnel Log display List of the last log settings State of control panel Status appears in the log display 16.14 Initializing the control and performing updates Extras Service Initialisierung...

  • Page 123: Initializing The Control

    Programming 16.14.1 Initializing the control Important Initializing the control resets all values to the factory default settings. All changes are lost. Only execute this option if you really want to return to the factory settings. Order Save your seam programs and seam sequences to a USB key before performing initialization.

  • Page 124: Cad Professional

    Programming Fig. 95: Performing an update of the control ① (1) - USB port 3. Switch on the machine.  The software update is performed automatically. Information If the automatic update does not function then you can use the menu items Extras Service Initialisierung (Initialize)

  • Page 125: Maintenance

    Maintenance 17 Maintenance WARNING Risk of injury from sharp parts! Punctures and cutting possible. Prior to any maintenance work, switch off the machine or set the machine to threading mode. WARNING Risk of injury from moving parts! Crushing possible. Prior to any maintenance work, switch off the machine or set the machine to threading mode.

  • Page 126: Cleaning

    Maintenance 17.1 Cleaning WARNING Risk of injury from flying particles! Flying particles can enter the eyes, causing injury. Wear safety goggles. Hold the compressed air gun so that the particles do not fly close to people. Make sure no particles fly into the oil pan. NOTICE Property damage from soiling! Sewing dust and thread residues can impair the operation of the...

  • Page 127: Cleaning The Motor Fan Mesh

    Maintenance Areas particularly susceptible to soiling: • Knife on the winder (4) • Area under the throat plate (3) • Hook (2) • Area around the needle (1) To clean the machine: 1. Remove any dust and thread residues using a compressed air gun or a brush.

  • Page 128: Lubricating

    Maintenance 17.2 Lubricating CAUTION Risk of injury from contact with oil! Oil can cause a rash if it comes into contact with skin. Avoid skin contact with oil. 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.

  • Page 129: Lubricating The Machine Head

    Maintenance 17.2.1 Lubricating the machine head Proper setting The oil level is between the minimum level marking and the maximum level marking. Fig. 98: Lubricating the machine head ① ② ③ (1) - Refill opening (3) - Minimum level marking (2) - Maximum level marking To lubricate the machine head: 1.

  • Page 130: Lubricating The Hook

    Maintenance 17.2.2 Lubricating the hook The approved oil quantity for hook lubrication is a factory specification. Proper setting 1. Hold a piece of blotting paper next to the hook (1) while sewing.  After sewing a stretch of approx. 1 m, the blotting paper will have been sprayed with a thin and even film of oil.

  • Page 131: Servicing The Pneumatic System

    Maintenance 17.3 Servicing the pneumatic system 17.3.1 Adjusting the operating pressure NOTICE Property damage from incorrect adjustment! Incorrect operating pressure can result in damage to the machine. Ensure that the machine is only used when the operating pressure is set correctly. Proper setting Refer to the Technical Data (...

  • Page 132: Draining The Water-Oil Mixture

    Maintenance 17.3.2 Draining the water-oil mixture NOTICE Property damage from excess liquid! Too much liquid can result in damage to the machine. Drain liquid as required. The collection tray (2) of the pressure regulator will show accumulation of a water-oil mixture. Proper setting The water-oil mixture must not rise up to the level of the filter element (1).

  • Page 133: Cleaning The Filter Element

    Maintenance 17.3.3 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. Fig. 102: Cleaning the filter element ① ② ③ (1) - Filter element (3) - Drain screw (2) - Collection tray To clean the filter element:...

  • Page 134: Servicing Specific Components

    Maintenance 17.4 Servicing specific components Checking the toothed belt WARNING Risk of injury from moving parts! Crushing possible. Switch off the machine before checking the condition of the toothed belt. The condition of the toothed belt must be checked once a month. Important A damaged toothed belt must be replaced immediately.

  • Page 135: Decommissioning

    Decommissioning 18 Decommissioning WARNING Risk of injury from a lack of care! Serious injuries may occur. ONLY clean the machine when it is switched off. Allow ONLY trained personnel to disconnect the machine. CAUTION Risk of injury from contact with oil! Oil can cause a rash if it comes into contact with skin.
  • Page 136 Decommissioning Service Instructions 911-210-10 - 00.0 - 06/2020...

  • Page 137: Disposal

    Disposal 19 Disposal CAUTION Risk of environmental damage from improper disposal! Improper disposal of the machine can result in serious environmental damage. ALWAYS comply with the national regulations regarding disposal. The machine must not be disposed of in the normal household waste. The machine must be disposed of in a suitable manner in accordance with all applicable national regulations.
  • Page 138 Disposal Service Instructions 911-210-10 - 00.0 - 06/2020...

  • Page 139: Troubleshooting

    Troubleshooting 20 Troubleshooting 20.1 Customer Service 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.com 20.2 Messages of the software Code Description...
  • Page 140 Troubleshooting Code Description Troubleshooting 1058 Sewing motor speed 1302 • Sewing motor defective • Replace sewing motor 1342 Sewing motor error • Check the cable from the pulse Control not receiving pulses from encoder in the motor to the control 1344 pulse encoder in motor •...
  • Page 141 Troubleshooting Code Description Troubleshooting 2255 Y-axis stepper motor overload • Eliminate sluggishness • Feed system not moving freely • Remove obstacles/adjust the motion • Obstacles to the feed motion 2256 Y-axis stepper motor overtemperature • Feed system not moving freely •...
  • Page 142 Troubleshooting Code Description Troubleshooting 3123 Oil sensor active Top off the oil 3210 Thread broken Re-thread the thread 3215 Bobbin empty (remaining thread Insert full bobbin counter) 3220 Bobbin empty (remaining thread Insert full bobbin counter) 3500 Error in calculating the contour data •...
  • Page 143 Troubleshooting Code Description Troubleshooting 8351 Test pins error • Switch off and on the machine • Software update • Notify DA Service 8400 Control panel has no valid program for Load the current program into the the DAC. control panel from a USB key. 8401 Control panel has no valid program for Load the current program into the...

  • Page 144: Errors In Sewing Process

    Troubleshooting 20.3 Errors in sewing process Error Possible causes Remedial action Unthreading at seam Needle thread tension is Check needle thread tension beginning too firm Thread breaking Needle thread and hook Check threading path thread have not been threaded correctly Needle is bent or sharp- Replace needle edged...
  • Page 145 Troubleshooting Error Possible causes Remedial action Loose stitches Thread tensions are not Check thread tensions adjusted to the sewing material, the sewing material thickness or the thread used Needle thread and hook Check threading path thread have not been threaded correctly Needle breakage Needle thickness is Use recommended needle...
  • Page 146 Troubleshooting Service Instructions 911-210-10 - 00.0 - 06/2020...
  • Page 147 Technical data 21 Technical data 21.1 Data and characteristic values Technical data Unit Type of stitches Hook type Vertical hook Number of needles Needle system 134/35 Needle strength [Nm] 80 - 180 Thread strength [Nm] Needle thread 10/3 Hook thread 20/3 Stitch length [mm] up to 12.7, dependent on seam pattern...
  • Page 148 Technical data 21.2 Requirements for fault-free operation Compressed air quality must conform to ISO 8573-1: 2010 [7:4:4]. Service Instructions 911-210-10 - 00.0 - 06/2020...
  • Page 150 DÜRKOPP ADLER AG Potsdamer Str. 190 33719 Bielefeld Germany Phone: +49 (0) 521 925 00 Email: service@duerkopp-adler.com www.duerkopp-adler.com...

This manual is also suitable for:

991-210-3020-10991-210-6020-10991-210-6055-10

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