DURKOPP ADLER 512-211-01, 532-211-01 Service Instructions Manual

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512-211-01
532-211-01
Service Instructions
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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
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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
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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
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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.
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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.
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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.
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About these instructions
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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.
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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
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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.
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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.
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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.
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Work principles

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
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(1) - Machine upper section
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Work principles
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

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
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Work principles
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.
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3.3.6 Removing and fitting the rear cover

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.
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Work principles

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).
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2. Raise both clamp feet (2).
⑤⑥
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.
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Work principles
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.
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Work principles
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Adjusting the light barriers

4 Adjusting the light barriers

4.1 Light barrier sensor disks

The light barrier sensor disks are used as a reference for positioning by the control unit.
WARNING
Risk of injury from moving parts!
Crushing possible. Switch the sewing machine off before adjusting the
light barriers.
Checking the correct setting
The 180° disk points to the front and its lower edge is precisely lined
up with the light barriers slots.
Faults caused by an incorrect setting
• Damage to fabric, wrinkling
• Incorrect needle position, needle jams in the hole
• Incorrect transport times
• Incorrect thread cutting
• Poor sewing results
Cover
• Remove rear cover (S. 16).
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Adjusting the light barriers
Fig. 13: Light barrier sensor disks
o
(1) - Thread trimmer sensor disk (2) - Thread wiper and fabric clamp sensor
disk

4.2 Adjusting the left and right switching flags

The switching flags are used as reference by the control unit for the posi­tion of the clamps in an X and Y-direction.
Checking the correct setting
The clamps are centered in both an X and Y-direction.
Faults caused by an incorrect setting
• Damage to the needle
• Incorrect needle position
Cover
• Remove the right-hand side cover (S. 14).
• Remove the left-hand side cover (S. 15).
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Adjusting the light barriers
Fig. 14: Adjusting the right switching flag
(1) - Screw (2) - Switching flag, right
Fig. 15: Adjusting the left switching flag
(1) - Screw (2) - Switching flag, left
Adjusting steps
1. Loosen the screw (1).
2. Adjust the switching flag (2) accordingly.
3. Set the zero point via the control unit.
4. Tighten the screw (1).
5. Reference the machine.

4.3 Thread clamp switching flag

The thread clamp switching flag is used as reference by the control unit for the thread clamp. The switching flag is located underneath the throat plate to the right and is factory set.
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Adjusting the hook and needle bar
512 532

5 Adjusting the hook and needle bar

The following 3 settings must be coordinated:
• Height of the needle bar
• Loop stroke position and needle guard
• Hook clearance to the needle

5.1 Adjusting the needle bar height

WARNING
Risk of injury from sharp and moving parts!
Crushing hazard and puncturing injuries due to moving and sharp parts.
Switch off the sewing machine before adjusting the height of the needle bar.
The needle bar has 4 marker lines which serve as an adjusting aid. The top two lines are valid for class 512, while the bottom two lines are valid for class 532.
Cover
• Remove the head cover ( S. 13).
Fig. 16: Adjusting the needle bar height
(1) - Screw (2) - Needle bar
Adjusting steps
(3) - Marker line for class 512 (4) - Marker line for class 532
1. Use the handwheel to set the needle bar at its lowest position.
2. Loosen the screw (1).
3. Adjust the height of the needle bar (2) so that the applicable upper marker line (3/4) is aligned with the needle bar bush. When doing this make sure that the needle bar (2) is not twisted.
4. Tighten the screw (1).
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Adjusting the hook and needle bar

5.2 Adjusting the loop stroke and needle guard

Loop stroke
The loop stroke is the path length from the lower dead center of the need- le bar to the position where the hook is in the loop stroke position.
Fig. 17: Loop stroke
WARNING
Risk of injury from sharp and moving parts!
Crushing hazard and puncturing injuries due to moving and sharp parts.
Switch off the sewing machine before adjusting the loop stroke and needle guard.
(1) - Center line of the needle (2) - Hook tip
Checking the correct setting
When the machine is in the loop stroke position, the hook tip should be located exactly on the center line of the needle. The needle must be aligned so that the surface of the groove is parallel to the running direction of the hook tip. The hook tip should be located in the lower third of the groove.
Faults caused by an incorrect setting
• Damage to the hook
• Damage to the needle
• Missing stitches
• Thread breakage
Order
Prerequisite:
• A straight and undamaged needle must be inserted (Operating
manual, Section 4.7 Changing needles).
(3) - Groove
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Adjusting the hook and needle bar
512 532
①⑤
②③
Cover
• Open the hook flap ( S. 17).
Fig. 18: Adjusting the loop stroke and needle guard
(1) - Hook tip (2) - Hook (3) - Driver (4) - Screw
(5) - Needle (6) - Marker line for class 512 (7) - Marker line for class 532
Adjusting steps
1. Use the handwheel to adjust the needle bar so that the corresponding marker line (6/7) is aligned with the needle bar bush.
2. Loosen the screw (4).
3. Remove the cover ring. When doing this make sure that the hook (2) does not work loose and fall.
4. Twist the driver (3) accordingly.
5. Shift the driver (3) axially so that the needle (5) rests against the driver tip and is easily pushed aside.
6. Insert the cover ring.
7. Tighten the screw (4).
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Adjusting the hook and needle bar
①③

5.3 Adjusting the distance between the hook tip and needle

Cover
• Open the hook flap ( S. 17).
Fig. 19: Adjusting the distance between the hook tip and needle
WARNING
Risk of injury from sharp and moving parts!
Crushing hazard and puncturing injuries due to moving and sharp parts.
Switch off the sewing machine before adjusting the distance between the hook tip and needle.
(1) - Screw (2) - Eccentric (3) - Eccentric safety screw (4) - Needle
(5) - Hook tip (6) - Tip of the hook path bearing (7) - Hook path bearing
Checking the correct setting
The hook tip (5) must be as close as possible to the groove of the needle, without touching it. The tip of the hook path bearing (6) should have a gap of 7.5 mm to the right side of the needle.
Adjusting steps
1. Loosen the screw (1).
2. Loosen the safety screw (3) of the eccentric.
3. Adjust the hook path bearing (7) axially with the eccentric (2):
Eccentric to the left: reduce distance.
Eccentric to the right: increase distance.
4. Twist the hook path bearing (7) in such a way that it has a clearance of 7.5 mm to the right-hand side.
5. Tighten the safety screw (3) of the eccentric.
6. Tighten the screw (1).
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Adjusting the thread trimmer

6 Adjusting the thread trimmer

For the thread trimmer to work correctly, you must set the thread puller blade and the counter blade.
WARNING
Risk of injury from sharp and moving parts!
Crushing hazard and puncturing injuries due to moving and sharp parts.
Switch off the sewing machine before adjusting the blades.
Faults caused by an incorrect setting
• Threads are not cut
• Threads are cut too long
Cover
• Remove the throat plate ( S. 17).
Fig. 20: Adjusting the blades
(1) - Needle guide (2) - Thread trimmer lever (3) - Screw for thread trimmer lever
Adjusting steps
1. Loosen the screw (3).
(4) - Counter blade screw (5) - Counter blade
2. Set a distance of 18.5 mm between the front of the throat plate and the thread trimmer lever (5).
3. Tighten the screw (3).
4. Loosen the counter blade screws (4).
5. Move the counter blade and set a distance of 0.5 mm between the needle guide (1) and the counter blade (5).
6. Tighten the counter blade screws (4).
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Adjusting the height of the fabric clamp lift

7 Adjusting the height of the fabric clamp lift

The following maximum heights apply when adjusting the fabric clamp lift:
• Max. height for class 512: 15 mm
• Max. height for class 532:
• 13 mm (Standard button clamp)
• 7 mm (Universal button clamp without shank shaper)
• 5 mm (Universal button clamp with shank shaper)
WARNING
Risk of injury from sharp and moving parts!
Crushing hazard and puncturing injuries due to moving and sharp parts.
Switch off the sewing machine before adjusting the fabric clamp lift.
Cover
• Remove the arm cover ( S. 14).
Fig. 21: Adjusting the height of the fabric clamp lift
(1) - Screw
Adjusting steps
1. Loosen the screw (1).
2. Adjust the height by turning the fabric clamp lift on the shaft. When doing this observe the values for the maximum height.
3. Tighten the screw (1).
Order
After changing the height of the fabric clamp lift always check the setting of the thread wiper as well.
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Adjusting the height of the fabric clamp lift
Adjusting the fabric clamping feet (class 512)
Faults caused by an incorrect setting
• The two fabric clamping feet do not raise and lower synchronously.
Fig. 22: Adjusting the fabric clampi n g fe e t
(1) - Screw
Adjusting steps
1. Loosen the screws (1).
2. Align the fabric clamping feet synchronously.
3. Tighten the screws (1).
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Adjusting the thread wiper
1.5 mm 23-25 mm

8 Adjusting the thread wiper

Fig. 23: Adjusting the thread wiper
WARNING
Risk of injury from sharp and moving parts!
Crushing hazard and puncturing injuries due to moving and sharp parts.
Switch off the sewing machine before adjusting the thread wiper.
(1) - Screw
Adjusting steps
1. Loosen the screw (1).
2. Adjust the thread wiper. When doing this observe the minimum distance of 1.5 mm to the needle and the distance range of 23 to 25 mm when pivoting. When using a thin needle set the distance at 23 mm.
3. Tighten the screw (1).
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Adjusting the thread regulator

9 Adjusting the thread regulator

The thread regulator determines the needle thread quantity to be guided around the hook. The required thread quantity depends on the thickness of the material to be sewn, thread strength, and stitch length.
Larger thread quantity for
• thick material
• high thread strengths
• large stitch lengths
Lower thread quantity for
• thin material
• low thread strengths
• small stitch lengths
Checking the correct setting
1. Open the hook flap (S. 17) and observe the thread running around the hook:
The needle thread loop runs without surplus and without jumping
around the largest hook diameter.
Faults caused by an incorrect setting
• Poor sewing results
Fig. 24: Adjusting the thread regulator
1
2
(1) - Thread regulator (2) - Fastening screw
Adjusting steps
1. Turn the handwheel and o bserve the run of the thread around the hook.
2. Loosen the fastening screw (2).
3. Move the thread regulator (1):
Larger thread quantity: Turn the regulator counterclockwise
Lower thread quantity: Turn the regulator clockwise
4. Tighten the fastening screw (2).
32 Service Instructions 512-211-01/532-211-01 - 01.0 - 10/2017
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Adjusting the winder
1
2
3
4

10 Adjusting the winder

10.1 Setting the fill volume

Correct setting
1. Wind onto an empty bobbin ( Operating manual, Section 4.4).
Winding stops automatically when the bobbin is filled to approx.
0.5 mm below the bobbin edge.
NOTICE
Property damage may occou!
When operated without sewing material the sewing feet and bobbin case in the hook can be damaged.
Enable the winding mode (Operating manual, Section 5.8 Winding) and remove the bobbin case from the hook to perform a test winding process.
Fig. 25: Setting the winder fill volume
(1) - Adjusting screw (2) - Clamping screw
Adjusting steps
Rough adjustment
1. Loosen the clamping screw (2).
2. Align the actuating lever (4):
Smaller fill quantity: Push towards bobbin.
Larger fill quantity: Push away from bobbin.
3. Tighten the clamping screw (2).
(3) - Thread guide plate (4) - Actuating lever
Fine adjustment
4. Loosen the adjusting screw (1).
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Adjusting the winder
5. Move the thread guide plate (3):
Smaller fill quantity: Push towards bobbin.
Larger fill quantity: Push away from bobbin.
6. Tighten the adjusting screw (1).

10.2 Adjusting the winding tension

Correct setting
The correct winding tension depends on the anti-friction properties and thickness of the thread.
Faults caused by an incorrect setting
• Wrinkled seams
• Poor sewing results
Fig. 26: Adjusting the winding tension
(1) - Adjusting knob
Adjusting steps
1. Turn the adjusting knob (2):
Greater tension: Turn clockwise
Less tension: Turn counterclockwise
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Programming
⑦⑧

11 Programming

This chapter describes service settings such as
The basic configuration of the machine
Test functions for individual elements of the machine
Calibration functions
Presets for programs and functions
Information regarding changes to the stitch length, thread tension, curve support, etc. as well as instructions for accessing and creating sewing programs can be found in the operating manual (Operating manual, Section 5 Settings via software).

11.1 Basic software operation

The software is controlled via the control panel.
Fig. 27: Control panel
Control panel buttons:
Button / LED Pos. Function
(1) USB button with LED
Saves/loads a sewing pattern to/from a USB stick.
(2) Needle thread clamp button with LED
Fixes needle thread during the first stitch. LED on = needle thread clamp on LED off = needle thread clamp off
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Button / LED Pos. Function
(3) Memory button
Processes the memory functions.
(4) Reset button
Deletes an error and restores settings.
(5) Ready button with LED
Change between programming and sewing mode. LED on = sewing mode LED off = programming mode
(6) Error LED
LED on = error
(7) Program display
Displays parameters.
(8) +/- Program buttons
Changes parameters and navigates forwards/backwards.
Programming
(9) Function display
Displays values of selected functions/programmes.
(10) +/- Function buttons
Changes values of functions/programmes.
(11) Selection button
Selects various functions. The corresponding function LED illuminates.
(12) Sewing pattern memory buttons
Saves sewing patterns.

1 1.2 Accessing the technician level

All of the settings in the service area are performed at the technician level.

11.2.1 Editing parameters in level 1

Prerequisite:
• The machine is in the programming mode, the LED in the Ready button
is off.
1. Press and hold the Memory button for 3 seconds.
The controller beeps 1x; the LED in the button illuminates.
The Program display shows the parameter numbers; the Function display shows the parameter values.
2. Press the +/- Program buttons to select other parameters.
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Programming
3. Press the Ready button to confirm the parameter.
The LED in the button illuminates.
4. Press the +/- Function buttons to change values.
5. Press the Reset button to reset a changed value.
6. Press the Ready button to save a change.
The LED in the button switches off.
7. Press the Memory button.
The LED in the button switches off.

11.2.2 Editing parameters in level 2

Prerequisite:
• The machine is in the programming mode, the LED in the Ready button
is off.
1. Press and hold the Memory button for 6 seconds.
The controller beeps 2x; the LED in the button illuminates.
The Program display shows the parameter numbers; the Function display shows the values.
2. Press the +/- Program buttons to select other parameters.
3. Press the Ready button to confirm the parameter.
The LED in the button illuminates.
4. Press the +/- Function buttons to change values.
5. Press the Reset button to reset a changed value.
6. Press the Ready button to save a change.
The LED in the button switches off.
7. Press the Memory button.
The LED in the button switches off.

1 1 .3 Setting the blade position

Prerequisite:
• The machine is in the programming mode, the LED in the Ready button
is off.
1. Press and hold the Memory button for 6 seconds.
The controller beeps 2x; the LED in the button illuminates.
The Program display shows the parameter numbers; the Function display shows the values.
2. Press the +/- Program buttons and select parameter U099.
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Programming
A
B
C
3. Press the Ready button to confirm the parameter.
The LED in the button illuminates. The Program display shows
"°°20".
4. Press button P1.
The thread trimmer sensor disk travels to position.
Fig. 28: Setting the blade position
5. Check to see if the hole of the thread puller blade and the needle guide of the throat plate are aligned:
Fig. 29: Checking the hole of the thread puller blade
Case A: The setting is wrong; the thread puller blade overlaps the
counter blade: Adjust blade sensor upwards.
Case B: The setting is wrong; the thread puller blade overlaps the
needle guide: Adjust blade sensor downwards.
Case C: The setting is correct.
6. Press button P1.
The thread trimmer sensor disk travels to position again.
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Programming
7. Check once again to see if the hole of the thread puller blade and the needle guide of the throat plate are accurately aligned.
8. Press the Ready button to save the change.
The LED in the button switches off.
9. Press the Memory button.
The LED in the button switches off.
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Programming

11.4 Loading software via a USB stick

NOTICE
Property damage may occur!
Damage to the machine as a result of interrupting the copying process.
Never remove the USB stick during the copying process. Only remove the USB stick after observing the specified time period.
If a new version of the software becomes available, it can be downloaded from www.duerkopp-adler.com and loaded onto a USB stick.
Important
The following files must be saved to the USB stick:
• FUYSTS.BT
• LEEYSTS.BT1
• BT1mot
• BT1PAT

11.4.1 Loading the main program

1. Switch on the controller.
2. Insert the USB stick.
3. Press the USB button and wait approx. 3 seconds.
4. Press the Memory button.
5. Press the +/- Function buttons to set value 5 in the Function display.
6. Press the Selection button.
The process for downloading to the controller starts.
Important
If a value is no longer shown in the Function display, the download pro­cess is complete. Now wait at least 25 seconds, otherwise it could corrupt the controller!
7. Switch off the controller.
8. Remove the USB stick.

11.4.2 Loading sewing patterns

1. Switch on the controller.
The current software version is briefly displayed.
2. Insert the USB stick.
3. Press the USB button and wait approx. 3 seconds.
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Programming
4. Press the Memory button.
5. Press the P5 button.
The process for downloading to the controller starts. This will take
approx. 4 minutes.
6. Press the Reset button.
7. Remove the USB stick.
The software transfer is complete.

11.4.3 Setting parameter U085 (class 532)

After installing new software, parameter U085 must be set for the button sewing machine.
Prerequisite:
• The machine is in the programming mode, the LED in the Ready button
is off.
1. Press and hold the Memory button for 6 seconds.
The LED in the button illuminates.
2. Select parameter number U085 by using the +/- Program buttons.
3. Press the Ready button.
4. Enter the function value 1 by using the +/- Function buttons.
5. Press the Selection button.

11.4.4 Checking the software version

1. Press and hold the Memory button for 6 seconds.
The controller beeps 2x; the LED in the button illuminates.
2. Press the +/- Program buttons and select parameter U097.
3. Press the Ready button.
The current software versions are displayed:
• M X.XX = Main program
• P X.XX = Control panel
• T X.XX = Servo motors
• A X.XX = Sewing patterns
4. Press the +/- Function buttons and check the respective software ver­sion.
5. Press the Ready button.
6. Press the Memory button.
The LED in the button switches off.
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Programming
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Maintenance

12 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.
This chapter describes maintenance work that needs to be carried out on a regular basis to extend the service life of the machine and achieve the desired seam quality.
Work to be carried out Operating hours
8 40 160 1000
Removing lint and thread remnants Clearing the fan screen at the control box Refilling oil Lubricating the sewing automat
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12.1 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!
Lint and thread remnants can impair the operation of the machine. Clean the machine as described.
Maintenance
NOTICE
Property damage from solvent-based cleaners!
Solvent-based cleaners will damage paintwork. Use only solvent-free substances for cleaning.
Lint and thread remnants should be removed after every 8 hours of ope­ration using a compressed air gun or a brush. When sewing very fluffy ma­terial, the machine should be cleaned more frequently.
A clean sewing machine provides protection from faults.
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Maintenance
Points that need to be cleaned particularly thoroughly:
Fig. 30: Cleaning and checking
(1) - Underside of throat plate (2) - Hook
• Area under the throat plate (1)
• Area around the hook (2)
• Bobbin housing and interior
• Thread cutter
• Area around the needle
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12.2 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. Only use oil that complies with the data in the instructions.
Maintenance
CAUTION
Risk of environmental damage from oil!
Oil is a pollutant and must not enter the sewage system or the soil.
Carefully collect up used oil. Dispose of used oil and oily machine parts in accordance with national regulations.
The machine is equipped with a central oil-wick lubrication system. The bearings are supplied from the oil reservoir.
For topping off the oil reservoir, use only lubricating oil DA 10 or oil of equivalent quality with the following specifications:
• Viscosity at 40 °C: 10 mm²/s
• Flash point: 150 °C
You can order the lubricating oil from our sales offices using the following part numbers:
Container Part no.
250 ml 904700001 1 1 l 9047 000012 2 l 9047 000013 5 l 9047 000014
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Maintenance

12.2.1 Checking the oil level

Checking the oil level of the hook
The sewing automat is equipped with a oil-wick lubrication system. The hook is supplied from the oil reservoir (1).
Fig. 31: Checking the oil level of the hook
(1) - Oil reservoir (2) - Oil filler opening
The oil level in the oil reservoir (1) must not drop below the lower red mar­king or be above the upper red marking.
1. Fill oil through the oil filler opening (2) up to the upper red marking.
Checking the oil level of the gear
Fig. 32: Checking the oil level of the gear (1)
(3) - Oil filler opening (4) - Screw
1. Unscrew the screw (4) from the oil filler opening at the back of the machine.
2. Fill oil through the oil filler opening (3).
For lubricating the gear maximum 110 ml are necessary.
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Maintenance
Fig. 33: Checking the oil level of the gear (2)
(5) - Oil gauge glass
When oil splashes at the oil gauge glass during operation enough oil
is filled in.

12.2.2 Lubricating with grease

Allowing the machine to operate at peak efficiency requires that its moving parts be lubricated sufficiently.
Lubrication points on the rear of the machine
Abb. 34: Lubrication points on the rear of the machine (1)
(1) - Cam disk (2) - Fleece
(3) - Joints
1. Apply an adequate amount of grease to the fleece (2) to lubricate the outer side of the cam disk (1).
2. Apply a small amount of grease to the joints (3) to ensure they remain flexible.
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Maintenance
Abb. 35: Lubrication points on the rear of the machine (2)
(4) - Roller (5) - Guide groove
3. Apply a small amount of grease to the inner guide groove (5) and the roller (4) from the outside.
4. Apply a small amount of grease to the joints (6).
Lubrication points on the machine head
Abb. 36: Lubrication points on the machine head
(6) - Joints
(7) - Thread lever guide (8) - Groove
1. Apply grease to cross head backside (9) and the connectors (10).
2. Lubricate the groove (8).
3. Lubricate the thread lever guide (7).
(9) - Cross head backside (10) - Connectors
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12.3 Adjusting the lubrication for the hook

NOTICE
Property damage may occur!
Damage to the oil wick when the screw is too tight.
Maintenance
Turn the lubricating screw maximum
Fig. 37: Adjusting the lubrication for the hook
(1) - Hole (2) - Lock screw
½ turn.
To adjust the lubrication for the hook:
1. Tilt the machine head.
2. Loosen and remove the lock screw (2).
The lubricating screw is located underneath the screw. The lubrica-
ting screw presses against the oil wick of the hook lubricator.
3. Adjusting the lubricating screw:
Increasing the lubrication: turn the lubricating screw coun-
terclockwise
Reducing the lubrication: turn the lubricating screw clockwise
Important
Turn the lubricating screw maximum
wise.
½ turn clockwise or counterclock-
4. Insert and tighten the lock screw (2).
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Decommissioning

13 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.
Avoid skin contact with oil. If oil has come into contact with your skin, wash the affected areas thoroughly.
To decommission the machine:
1. Switch off the machine
2. Unplug the power plug.
3. If applicable, disconnect the machine from the compressed air supply.
4. Remove residual oil from the oil pan using a cloth.
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.
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Decommissioning
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Disposal

14 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. When disposing of the machine, be aware that it consists of a range of
different materials (steel, plastic, electronic components, etc.). Follow the national regulations when disposing these materials.
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Disposal
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Troubleshooting

15 Troubleshooting

15.1 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

15.2 Messages of the software

Please contact customer service if an error occurs that is not described here. Do not attempt to correct the error yourself.
Error Meaning Possible cause
E 8 Error table data Unable to read the table
data
E 1 0 Error sewing pattern
number
E 3 0 Error needle bar
position top
E 4 0 Error sewing field Sewing field exceeded • Press the Reset button.
E 4 2 Error scaling Sewing length is below
E 4 5 Error sewing pattern
data
The selected sewing pat­tern is not saved in ROM or is set to non-readable. The sewing pattern is "0"
The needle bar is not at the top position
10 mm Sewing pattern data cannot
be applied
Remedial measures Process in the order specified!
• Save the table data again.
• Press the Reset button to confirm the sewing pattern number.
• Check the connections.
• Turn the needle bar to the top dead center position.
• Check X/Y scaling.
• Press the Reset button.
• Check sewing pattern and X/Y scaling.
• Press the Reset button.
• Check ROM.
E 5 0 Pause Reset button pressed while
sewing. Sewing machine stopped.
E 3 0 2 Error machine head Machine head has moved. • Fold back machine head.
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• Press the Reset button.
• Actuate the thread trimmer.
• Restart the sewing process.
Page 58
Troubleshooting
Error Meaning Possible cause
E 3 0 5 Error thread trimmer
position
E 3 0 6 Error thread catcher
position
E 3 3 2 Error clamp foot
position
E 5 0 1 Data read error Data not available or in the
E 5 0 2 USB read error MOT file error • Save the data to a USB stick again. E 5 0 3 SUM read error CHECKSUM data error in
E 5 0 4 End block error No end block in the MOT
E 5 0 5 USB read error USB stick not found • Set main switch to OFF.
E 5 0 6 USB read error Unable to read U01 ~ U10. • Set main switch to OFF.
Thread trimmer blade not at home position
Thread catcher not at home position
Clamp foot not at home position
wrong format
MOT file
file
Remedial measures Process in the order specified!
• Set main switch to OFF.
• Check sensor.
• Set main switch to OFF.
• Check sensor.
• Set main switch to OFF.
• Check sensor.
• Save the data to a USB stick again.
• Save the CHECKSUM file to a USB stick again.
• Save the end block file to a USB stick again.
• Set main switch to ON.
• Reinsert USB stick.
• Set main switch to ON.
• Reinsert USB stick.
E 5 0 7 Read error own
sewing patterns
E 5 0 8 File error own
sewing patterns
E 5 0 9 File error own
sewing patterns
E 5 1 0 File error own
sewing patterns
E 5 1 1 USB write error File with the same name
E 5 1 2 USB read error Data cannot be loaded
E 5 1 3 USB write error Data cannot be copied to
E 5 5 0 Data write error Flash memory transfer
E 5 5 1 Internal process
error
U01 ~ U10 read error • Download the data again.
U01 ~ U10 read error • Check file type.
U01 ~ U10 read error • Check file type.
U01 ~ U10 read error • Check file type.
already exists
from USB stick
USB stick.
error
Softwar error • Set main switch to OFF.
• Save data to USB again.
• Delete or rename file.
• Check USB stick.
• Reinsert USB stick.
• Check USB stick.
• Reinsert USB stick.
• Set main switch to OFF.
• Repeat process.
• Replace the mainboard.
• Repeat process.
• Replace the mainboard.
• Update software.
E770375Motor signal error Encoder / motor has no sig-
nal
E 7 3 6 Motor rotation error Motor stops / encoder has
no signal
56 Service Instructions 512-211-01/532-211-01 - 01.0 - 10/2017
• Check motor / encoder.
• Check motor / encoder.
Page 59
Troubleshooting
Error Meaning Possible cause
E 7 3 7 Error Z phase Z signal no longer changes • Check motor / encoder. E 7 3 8 Error Z phase Z signal inaccurate /
encoder has no signal
E 9 0 7 Error search X-axis X-axis sensor does not res-
pond
E 9 0 8 Error search Y-axis Y-axis sensor does not res-
pond
E 9 1 0 Error clamp foot
search
E 9 1 1 Error clamp foot
motor E 9 1 2 Internal error - • Notify DA Service E 9 1 3 Error thread catcher
search E 9 1 4 Error thread catcher
motor
Clamp foot sensor does not respond
Clamp foot motor does not operate corrrectly
Thread catcher sensor does not respond
Thread catcher motor does not operate corrrectly
Remedial measures Process in the order specified!
• Check motor / encoder.
• Set main switch to OFF.
• Check sensor.
• Set main switch to OFF.
• Check sensor.
• Set main switch to OFF.
• Check sensor.
• Set main switch to OFF.
• Check motor and connection.
• Set main switch to OFF.
• Check sensor.
• Set main switch to OFF.
• Check motor and connection.
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15.3 Errors in sewing process

Error Possible causes Remedial action
Troubleshooting
Unthreading at seam beginning
Thread breaking Needle thread and hook
Needle thread tension is too firm
thread have not been threaded correctly
Needle is bent or sharp­edged
Needle is not inserted correctly into the needle bar
The thread used is unsuitable
Thread tensions are too tight for the thread used
Thread-guiding parts, such as thread tube, thread guide or thread take-up disk, are sharp-edged
Throat plate, hook or spread have been damaged by the needle
Check needle thread tension
Check threading path
Replace the needle
Insert the needle correctly into the needle bar
Use recommended thread
Check thread tensions
Check threading path
Have parts reworked by qualified specialists
Missing stitches Needle thread and hook
thread have not been threaded correctly
Needle is blunt or bent Replace the needle Needle is not inserted
correctly into the needle bar
The needle thickness used is unsuitable
The reel stand is installed incorrectly
Thread tensions are too tight
Throat plate, hook or spread have been damaged by the needle
Check threading path
Insert the needle correctly into the needle bar
Use recommended needle thickness
Check the assembly of the reel stand
Check thread tensions
Have parts reworked by qualified specialists
58 Service Instructions 512-211-01/532-211-01 - 01.0 - 10/2017
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Troubleshooting
Error Possible causes Remedial action
Loose stitches Thread tensions are not
adjusted to the sewing material, the sewing material thickness or the thread used
Needle thread and hook thread have not been threaded correctly
Needle breakage Needle thickness is
unsuitable for the sewing material or the thread
Check thread tensions
Check threading path
Use recommended needle thickness
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Troubleshooting
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Technical data

16 Technical data

Data and characteristic values
Technical data Unit Class 512 Class 532
Type of stitches 301 301 Hook type oscillating hook oscillating hook Number of needles 1 1 Needle system 134
DPx5
Needle strength [Nm] 134: 80 - 110
DPx5: 12 - 18
Speed maximum Speed on delivery Mains voltage [V] 230 230
Mains frequency [Hz] 50/60 50/60 Length [mm] 660 660 Width [mm] 230 230 Height [mm] 430 430 Weight [kg] 69 69
-1
[min [min-1]
]
3000 3000 2700 2700
135x17
DPx17
135x17: 80 - 110
DPx17: 12 - 8
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Technical data
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Appendix

17 Appendix

Wiring diagram
Fig. 38: Wiring diagram (1)
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Fig. 39: Wiring diagram (2)
Appendix
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Appendix
Fig. 40: Wiring diagram (3)
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Fig. 41: Wiring diagram (4)
Appendix
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Appendix
Fig. 42: Wiring diagram (5)
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Appendix
68 Service Instructions 512-211-01/532-211-01 - 01.0 - 10/2017
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Page 72
DÜRKOPP ADLER AG
Potsdamer Straße 190 33719 Bielefeld GERMANY Phone +49 (0) 521 / 925-00 E-mail service@duerkopp-adler.com www.duerkopp-adler.com
Subject to design changes - Part of the machines shown with additional equipment - Printed in Germany
© Dürkopp Adler AG - Service Instructions - 0791 512641 EN - 01.0 - 10/2017
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