DURKOPP ADLER 512-211-01, 532-211-01 Service Instructions Manual
512-211-01
532-211-01
Service Instructions
IMPORTANT
READ CAREFULLY BEFORE USE
KEEP FOR FUTURE REFERENCE
All rights reserved.
Property of Dürkopp Adler AG and protected by copyright. Any reuse of these contents, inclu-
ding extracts, is prohibited without the prior written approval of Dürkopp Adler AG.
Copyright © Dürkopp Adler AG 2017
Table of contents
1 About these instructions ...........................................................3
1.1 For whom are these instructions intended?.................................. 3
1.2 Representation conventions – symbols and characters...............3
1.3 Other documents..........................................................................4
1.4 Liability..........................................................................................5
2 Safety...........................................................................................7
2.1 Basic safety instructions...............................................................7
2.2 Signal words and symbols used in warnings................................8
3 Work principles......................................................................... 11
3.1 Order of settings.........................................................................11
3.2 Cable routing..............................................................................11
3.3 Removing the covers..................................................................12
3.3.1 Access to the machine bottom section....................................... 12
3.3.2 Removing and fitting the head cover..........................................13
3.3.3 Removing and fitting the arm cover............................................14
3.3.4 Removing and fitting the right-hand side cover..........................14
3.3.5 Removing and fitting the left-hand side cover ............................15
3.3.6 Removing and fitting the rear cover............................................16
3.3.7 Opening and closing the hook flap.............................................17
3.3.8 Removing and inserting the throat plate.....................................17
3.4 Surfaces on shafts......................................................................19
4 Adjusting the light barriers...................................................... 21
4.1 Light barrier sensor disks ...........................................................21
4.2 Adjusting the left and right switching flags..................................22
4.3 Thread clamp switching flag.......................................................23
5 Adjusting the hook and needle bar......................................... 24
5.1 Adjusting the needle bar height..................................................24
5.2 Adjusting the loop stroke and needle guard...............................25
5.3 Adjusting the distance between the hook tip and needle ...........27
6 Adjusting the thread trimmer .................................................. 28
7 Adjusting the height of the fabric clamp lift...........................29
8 Adjusting the thread wiper ...................................................... 31
9 Adjusting the thread regulator................................................ 32
10 Adjusting the winder................................................................ 33
10.1 Setting the fill volume .................................................................33
10.2 Adjusting the winding tension.....................................................34
11 Programming ............................................................................35
11.1 Basic software operation............................................................35
11.2 Accessing the technician level....................................................36
11.2.1 Editing parameters in level 1 ......................................................36
11.2.2 Editing parameters in level 2 ......................................................37
11.3 Setting the blade position...........................................................37
11.4 Loading software via a USB stick............................................... 40
11.4.1 Loading the main program..........................................................40
Service Instructions 512-211-01/532-211-01 - 01.0 - 10/2017 1
Table of contents
11.4.2 Loading sewing patterns.............................................................40
11.4.3 Setting parameter U085 (class 532)...........................................41
11.4.4 Checking the software version ...................................................41
12 Maintenance..............................................................................43
12.1 Cleaning .....................................................................................44
12.2 Lubricating..................................................................................46
12.2.1 Checking the oil level..................................................................47
12.2.2 Lubricating with grease...............................................................48
12.3 Adjusting the lubrication for the hook .........................................50
13 Decommissioning.....................................................................51
14 Disposal.....................................................................................53
15 Troubleshooting .......................................................................55
15.1 Customer Service.......................................................................55
15.2 Messages of the software...........................................................55
15.3 Errors in sewing process ............................................................58
16 Technical data...........................................................................61
17 Appendix ...................................................................................63
2 Service Instructions 512-211-01/532-211-01 - 01.0 - 10/2017
About these instructions
1.
2.
…
1 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 ( S. 35).
Consider the instructions part of the product and store them in a place
where they are readily available.
1.1 For whom are these instructions intended?
These instructions are intended for:
With regard to minimum qualification and other requirements to be met by
personnel, please also follow the chapter Safety ( S. 7).
• Specialists:
This group has the appropriate technical training for performing
maintenance or repairing malfunctions.
1.2 Representation conventions – symbols and characters
Various information in these instructions is represented or highlighted by the
following characters in order to facilitate easy and quick understanding:
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 components to be set.
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.
Service Instructions 512-211-01/532-211-01 - 01.0 - 10/2017 3
About these instructions
•
Lists are marked by bullet points.
Result of performing an operation
Change to the machine or on the display/control panel.
Important
Special attention must be paid to this point when performing a step.
Information
Additional information, e.g. on alternative operating options.
Order
Specifies the work to be performed before or after a setting.
References
Reference to another section in these instructions.
Safety Important warnings for the user of the machine are specifically marked.
Since safety is of particular importance, hazard symbols, levels of danger
and their signal words are described separately in the chapter Safety
( S. 7).
Location
information
If no other clear location information is used in a figure, indications of right
or left are always from the user's point of view.
1.3 Other documents
The machine includes components from other manufacturers. Each manufacturer has performed a hazard assessment for these purchased parts
and confirmed their design compliance with applicable European and national regulations. The proper use of the built-in components is described
in the corresponding manufacturer's instructions.
4 Service Instructions 512-211-01/532-211-01 - 01.0 - 10/2017
About these instructions
1.4 Liability
All information and notes in these instructions have been compiled in
accordance with the latest technology and the applicable standards and
regulations.
Dürkopp Adler cannot be held liable for any damage resulting from:
Transport
Dürkopp Adler cannot be held liable for breakage and transport damages.
Inspect the delivery immediately upon receiving it. Report any damage
to the last transport manager. This also applies if the packaging is not
damaged.
• Breakage and damage during transport
• Failure to observe these instructions
• Improper use
• Unauthorized modifications to the machine
• Use of untrained personnel
• Use of unapproved parts
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 512-211-01/532-211-01 - 01.0 - 10/2017 5
About these instructions
6 Service Instructions 512-211-01/532-211-01 - 01.0 - 10/2017
Safety
2 Safety
This chapter contains basic information for your safety. Read the instructions carefully before setting up or operating the machine. Make sure to
follow the information included in the safety instructions. 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.
Work on live components and equipment is prohibited. Exceptions are
defined in the DIN VDE 0105.
For the following work, switch off the machine at the main switch or
disconnect the power plug:
• Replacing the needle or other sewing tools
• Leaving the workstation
• Performing maintenance work and repairs
• Threading
Missing or faulty parts could impair safety and damage the machine.
Only use original parts from the manufacturer.
Transport Use a lifting carriage or forklift to transport the machine. Raise the machine
max. 20 mm and secure it to prevent it from slipping off.
Setup The connecting cable must have a power plug approved in the relevant
country. The power plug may only be assembled to the power cable by
qualified specialists.
Obligations
of the operator
Follow the country-specific safety and accident prevention regulations and
the legal regulations concerning industrial safety and the protection of the
environment.
All the warnings and safety signs on the machine must always be in legible
condition. Do not remove!
Missing or damaged warnings and safety signs must be replaced
immediately.
Requirements
to be met by
the personnel
Only qualified specialists may:
• set up the machine
• perform maintenance work and repairs
• perform work on electrical equipment
Only authorized persons may work on the machine and must first have
understood these instructions.
Service Instructions 512-211-01/532-211-01 - 01.0 - 10/2017 7
Safety
Operation Check the machine during operating for any externally visible damage.
Stop working if you notice any changes to the machine. Report any changes
to your supervisor. Do not use a damaged machine any further.
Safety
equipment
Safety equipment should not be removed or deactivated. If it is essential
to remove or deactivate safety equipment for a repair operation, it must be
assembled and put back into operation immediately afterward.
2.2 Signal words and symbols used in warnings
Warnings in the text are distinguished by color bars. The color scheme is
based on the severity of the danger. Signal words indicate the severity of
the danger.
Signal words Signal words and the hazard they describe:
Signal word Meaning
DANGER (with hazard symbol)
If ignored, fatal or serious injury will result
WARNING (with hazard symbol)
If ignored, fatal or serious injury can result
CAUTION (with hazard symbol)
If ignored, moderate or minor injury can result
CAUTION (with hazard symbol)
If ignored, environmental damage can result
NOTICE (without hazard symbol)
If ignored, property damage can result
Symbols The following symbols indicate the type of danger to personnel:
Symbol Type of danger
General
Electric shock
8 Service Instructions 512-211-01/532-211-01 - 01.0 - 10/2017
Safety
Symbol Type of danger
Puncture
Crushing
Environmental damage
Examples Examples of the layout of warnings in the text:
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.
WARNING
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 seri-
ous or even fatal injury if ignored.
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
moderate or minor injury if the warning is ignored.
Service Instructions 512-211-01/532-211-01 - 01.0 - 10/2017 9
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 envi-
ronmental damage if ignored.
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.
10 Service Instructions 512-211-01/532-211-01 - 01.0 - 10/2017
Work principles
3 Work principles
3.1 Order of settings
Observe order Always adhere to the specified sequence for the individual setting steps.
Always observe all notes marked with a in the margin on prerequisites
and follow-up settings.
NOTICE
Property damage may occur!
Machine damage possible due to incorrect order.
Always adhere to the working order specified in this manual.
Binding the cable
together
3.2 Cable routing
Ensure that all cables in the machine are laid in such a way that moving
parts are not impaired in their ability to function correctly.
1. Lay excessively long cables neatly in proper cable snakes.
2. Tie the snakes together using a cable tie.
If possible, bind the snakes to fixed parts.
The cables must be fixed firmly in place.
3. Cut off any protruding part of the cable tie.
NOTICE
Property damage may occur!
Machine damage and malfunctions can be caused by laying the
cables incorrectly.
Excess cabling may obstruct moving machine parts in their ability to
function correctly. This will affect the sewing function and may cause
damage.
Lay excess cabling as described above.
Service Instructions 512-211-01/532-211-01 - 01.0 - 10/2017 11
Work principles
①
3.3 Removing the covers
NOTICE
Property damage may occur!
Machine damage and malfunctions can be caused by laying the
cables incorrectly.
Excess cabling may obstruct moving machine parts in their ability to
function correctly. This will affect the sewing function and may cause
damage.
Lay excess cabling as described above.
WARNING
Risk of injury from moving parts!
Crushing possible.
Switch the sewing machine off before you remove
the covers or refit them.
In many types of setting work, you will have to remove the machine covers
first in order to access the components.
Described here is how to remove the individual covers and how to reattach
them. Just the cover that needs to be removed is then specified in the text
for that particular type of setting work.
3.3.1 Access to the machine bottom section
In order to access the components at the machine bottom section, you
must first tilt the machine upper section to the left.
Fig. 1: Tilting the machine upper section to the left and setting it upright
12 Service Instructions 512-211-01/532-211-01 - 01.0 - 10/2017
(1) - Machine upper section
Work principles
①
②
③
Tilting the machine upper section to the left
1. Tilt the machine upper section (1) to the left as far as possible.
Setting the machine upper section upright
1. Set the upper machine section (1) upright.
3.3.2 Removing and fitting the head cover
Fig. 2: Removing and fitting the head cover
(1) - Screw
(2) - Eye guard
Removing the head cover
1. Unscrew the eye guard (2).
2. Loosen both screws (1).
3. Remove the head cover (3).
Fitting the head cover
1. Fit the head cover (3).
2. Tighten both screws (1).
3. Tighten the eye guard (2).
(3) - Head cover
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3.3.3 Removing and fitting the arm cover
①
②
①
②
Fig. 3: Removing and fitting the arm cover
Work principles
(1) - Screw (2) - Arm cover
Removing the arm cover
1. Loosen all screws (1).
2. Remove the arm cover (2).
Fitting the arm cover
1. Fit the arm cover (2).
2. Tighten all screws (1) firmly in place.
3.3.4 Removing and fitting the right-hand side cover
Fig. 4: Removing and fitting the right-hand side cover
(1) - Screw (2) - Right-hand side cover
14 Service Instructions 512-211-01/532-211-01 - 01.0 - 10/2017
Work principles
①
②
Removing the right-hand side cover
1. Loosen both screws (1).
2. Remove the right-hand side cover (2).
Fitting the right-hand side cover
1. Fit the right-hand side cover(2).
2. Tighten both screws (1).
3.3.5 Removing and fitting the left-hand side cover
Fig. 5: Removing and fitting the left-hand side cover
(1) - Screw (2) - Left-hand side cover
Removing the left-hand side cover
1. Loosen all 3 screws (1).
2. Remove the left-hand side cover (2).
Fitting the left-hand side cover
1. Fit the left-hand side cover (2).
2. Tighten all 3 screws (1) firmly in place.
Service Instructions 512-211-01/532-211-01 - 01.0 - 10/2017 15
3.3.6 Removing and fitting the rear cover
①
②
Fig. 6: Removing and fitting the rear cover
(1) - Screw (2) - Rear cover
Work principles
Removing the rear cover
1. Loosen all 4 screws (1) on the rear cover (2).
2. Remove the rear cover (2).
Fitting the rear cover
1. Fit the rear cover (2).
2. Tighten all 4 screws (1) on the rear cover (2) firmly in place.
16 Service Instructions 512-211-01/532-211-01 - 01.0 - 10/2017
Work principles
①
①
②
③
④
3.3.7 Opening and closing the hook flap
Fig. 7: Opening and closing the hook flap
(1) - Hook flap
Opening the hook flap
1. Fold down the hook flap (1).
Closing the hook flap
1. Fold up the hook flap (1).
3.3.8 Removing and inserting the throat plate
Fig. 8: Removing and inserting the throat plate (1)
(1) - Springs of the fabric clamp
(2) - Clamp feet
(3) - Screw
(4) - Work surface
Removing the throat plate
1. Remove both springs of the fabric clamp (1).
Service Instructions 512-211-01/532-211-01 - 01.0 - 10/2017 17
2. Raise both clamp feet (2).
⑤⑥
⑦
⑧
3. Loosen the screw (3) for the work surface (4).
4. Remove the work surface (4).
Fig. 9: Removing and inserting the throat plate (2)
Work principles
(5) - Thread puller blade connecting rod (6) - Screw
5. Open the hook flap ( S. 17).
6. Loosen the screw (6).
7. Unhinge the thread puller blade connecting rod (5).
Fig. 10: Removing and inserting the throat plate (3)
(7) - Throat plate (8) - Screw
8. Loosen all 4 screws (8).
9. Remove the throat plate (7) upwards.
18 Service Instructions 512-211-01/532-211-01 - 01.0 - 10/2017
Work principles
⑨
2
1
Inserting the throat plate
Fig. 11: Removing and inserting the throat plate (4)
(9) - Connecting rod pin for needle thread clamp
1. Insert the throat plate (7) from above. When doing this make sure that
the hole in the needle thread clamp, which is located underneath the
throat plate, and the connecting rod pin of the needle thread clamp (9)
are mounted.
2. Mount the thread puller blade connecting rod (5) and make sure that
the connecting rod grips properly.
3. Tighten all 4 screws (8) of the throat plate firmly in place.
4. Tighten the screw (6).
5. Close the hook flap ( S. 17).
6. Fit the work surface (4).
7. Tighten the screw (3) for the work surface (4) firmly in place.
8. Mount both springs of the fabric clamp (1).
3.4 Surfaces on shafts
Fig. 12: Surfaces on shafts
(1) - Surface (2) - Shaft
Some shafts have flat surfaces at those points where the components are
screwed on. This strengthens the connection and setting work is made easier.
Always make sure that the whole screw is seated completely on the surface.
Service Instructions 512-211-01/532-211-01 - 01.0 - 10/2017 19
Work principles
20 Service Instructions 512-211-01/532-211-01 - 01.0 - 10/2017
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