Duerkopp Adler 511 Operating instructions

511
CNC-Automat für Riegel- und Kurznähte
CNC automat for bartacking seams
and short seams
Bedienanleitung / Operating Instructions
Aufstellanleitung / Installation Instructions
Serviceanleitung /Service Instructions
Postfach 17 03 51, D-33703 Bielefeld Potsdamer Straße 190, D-33719 Bielefeld
Telefon [phone] Telefax+49(0)521/9252435www.duerkopp-adler.com
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Ausgabe / Edition: Änderungsindex Teile-Nr./Part.-No.:
08/2009 Rev. index: 00.0 Printed in Federal Republic of Germany 0791 511001

Alle Rechte vorbehalten.
Eigentum der Dürkopp Adler AG und urheberrechtlich geschützt. Jede, auch auszugsweise
Wiederverwendung dieser Inhalte ist ohne vorheriges schriftliches Einverständnis der Dürkopp Adler AG
verboten.
All rights reserved.
Property of Dürkopp Adler AG and copyrighted. Reproduction or publication of the content in any manner,
even in extracts, without prior written permission of Dürkopp Adler AG, is prohibited.
Copyright © Dürkopp Adler AG - 2009

Foreword
This instruction manual is intended to help the user to become familiar
with the machine and take advantage of its application possibilities in
accordance with the recommendations.
The instruction manual contains important information on how to
operate the machine securely, properly and economically. Observation
of the instructions eliminates danger, reduces costs for repair and
down-times, and increases the reliability and life of the machine.
The instruction manual is intended to complement existing national
accident prevention and environment protection regulations.
The instruction manual must always be available at the machine/sewing
unit.
The instruction manual must be read and applied by any person that is
authorized to work on the machine/sewing unit. This means:
–Operation, including equipping, troubleshooting during the work
cycle, removing of fabric waste,
–Service (maintenance, inspection, repair) and/or
–Transport.
The user also has to assure that only authorized personnel work on the
machine.
The user is obliged to check the machine at least once per shift for
apparent damages and to immediatly report any changes (including the
performance in service), which impair the safety.
The user company must ensure that the machine is only operated in
perfect working order.
Never remove or disable any safety devices.
If safety devices need to be removed for equipping, repairing or
maintaining, the safety devices must be remounted directly after
completion of the maintenance and repair work.
Unauthorized modification of the machine rules out liability of the
manufacturer for damage resulting from this.
Observe all safety and danger recommendations on the machine/unit!
The yellow-and-black striped surfaces designate permanend danger
areas, eg danger of squashing, cutting, shearing or collision.
Besides the recommendations in this instruction manual also observe
the general safety and accident prevention regulations!

General safety instructions
The non-observance of the following safety instructions can cause
bodily injuries or damages to the machine.
1. The machine must only be commissioned in full knowledge of the
instruction book and operated by persons with appropriate training.
2. Before putting into service also read the safety rules and
instructions of the motor supplier.
3. The machine must be used only for the purpose intended. Use of
the machine without the safety devices is not permitted. Observe all
the relevant safety regulations.
4. When gauge parts are exchanged (e.g. needle, presser foot, needle
plate, feed dog and bobbin) when threading, when the workplace is
left, and during service work, the machine must be disconnected
from the mains by switching off the master switch or disconnecting
the mains plug.
5. Daily servicing work must be carried out only by appropriately
trained persons.
6. Repairs, conversion and special maintenance work must only be
carried out by technicians or persons with appropriate training.
7. For service or repair work on pneumatic systems, disconnect the
machine from the compressed air supply system (max. 7-10 bar).
Before disconnecting, reduce the pressure of the maintenance unit.
Exceptions to this are only adjustments and functions checks made
by appropriately trained technicians.
8. Work on the electrical equipment must be carried out only by
electricians or appropriately trained persons.
9. Work on parts and systems under electric current is not permitted,
except as specified in regulations DIN VDE 0105.
10. Conversion or changes to the machine must be authorized by us
and made only in adherence to all safety regulations.
11. For repairs, only replacement parts approved by us must be used.
12. Commissioning of the sewing head is prohibited until such time as
the entire sewing unit is found to comply with EC directives.
13. The line cord should be equipped with a country-specific mains
plug. This work must be carried out by appropriately trained
technicians (see paragraph 8).
It is absolutely necessary to respect the safety
instructions marked by these signs.
Danger of bodily injuries !
Please note also the general safety instructions.

Contents Page:
Part 3: Service Instructions for the 511 Class
(Edition 08.2009)
1. General .................................................... 3
2. Arm Shaft
2.1 Preparatoryadjustmentwork........................................ 4
2.2 Assemblyofthecrank............................................ 5
2.3 Armshaftpositioning ............................................ 6
2.4 Bevel gear for the hand wheel ....................................... 8
2.5 Adjust bobbin winder............................................. 9
2.6 Thread-trimmer cam ............................................. 10
2.7 Crankshaft drive to the hook shaft..................................... 11
2.8 Sewingmotorclutch............................................. 12
2.9 Referencepositionofthesewingmotor ................................. 13
2.9.1 Positionoftheinitiator............................................ 13
2.9.2 Adjustreferenceposition.......................................... 14
3. Hook, Looping Stroke, and Needle Bar Height
3.1 Drivershaft .................................................. 17
3.2 Gearsegmentonthecamshaft ...................................... 18
3.3 Gearsegmenttothedrivershaft...................................... 19
3.4 Needle bar height............................................... 20
3.5 Distance between hook tip and needle .................................. 21
3.6 Looping stroke and needle protection................................... 22
4. Thread-Guiding Parts
4.1 Threadtake-uplever............................................. 23
4.2 Thread regulator ............................................... 25
5. Thread Trimmer
5.1 Thread trimmer magnet ........................................... 26
5.2 Position of the hook knife .......................................... 27
5.3 Cutting pressure / Position of the stationary knife ........................... 28
5.4 Thread guide sheet.............................................. 30
6. Material Feed
6.1 Gauge for reference position ........................................ 31
6.2 Referenceposition.............................................. 32
6.3 Position of the fabric clamps and the rest plate to the needle .................... 34
6.4 Fabricclamplifting.............................................. 35
7. Oil Lubrication ................................................ 36
7.1 Oilcirculation................................................. 37
7.2 Oilpump.................................................... 38
8. Replacing the Control Unit ........................................ 39
9. Maintenance ................................................. 39
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1. General
These service instructions describe the adjustment of the automatic
bartacker 511.
CAUTION !
The operations described in these service instructions may only be
carried out by qualified staff or other properly trained persons!
Caution – Risk of injury !
Always switch off the main switch before any repair, alteration or
maintenance.
Adjustment work and function testing that takes place while the
machine is running should be carried out only under observance of all
safety measures and with the greatest possible caution.
These service instructions describe the adjustment of the automatic
bartacker in a logical order. Please observe that various setting
positions are dependent on each other. Thus it is essential that the
settings be conducted while keeping to the order described. For all
adjustments of parts involved in the stitch formation, a new undamaged
needle must be inserted.
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2. Arm Shaft
2.1 Preparatory adjustment work
Some of the adjustments at the arm shaft 1 are easier to carry out if
the thread trimming mechanism 3 is removed.
Caution – Risk of injury !
Turnthemainswitchoff.
Remove and mount the thread trimming mechanism only when the
automatic bartacker is switched off.
Remove mechanism
–Unscrew arm cover.
–Loosen screw 4 at the thread trimmer magnet.
–Unscrew screws 2 and 5 and take off thread trimming
mechanism 3.
Mount mechanism
–Push thread trimming mechanism 3 on the magnet and place it on
the machine head.
–Insert screws 2 and 5 and screw tight.
–Tighten screw 4 at the thread trimmer magnet.
–Adjust thread trimmer (see chapter 5).
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2.2 Assembly of the crank
Caution – Risk of injury !
Turnthemainswitchoff.
Remove and mount the crank only when the automatic bartacker is
switched off.
Rule:
The crank 4 has to be mounted on the arm shaft 1 in such a way that
the pivot 3 of the screw 2 reaches into the drill-hole on the arm shaft.
The screw 2 is the first screw in the direction of rotation.
Assembly
–Push crank 4 on arm shaft 1.
–Turn crank 4 so that its first drill-hole in the direction of rotation is
located above the drill-hole in the arm shaft 1. Insert screw 2 with
pivot 3 and screw tight.
–Insert screw 5 and tighten.
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3
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2.3 Arm shaft positioning
Caution – Risk of injury !
Turnthemainswitchoff.
Check and adjust the position of the arm shaft only when the automatic
bartacker is switched off.
Rule and control
The arm shaft 1 should have no axial backlash, but it must not move
too sluggishly.
–Check the arm shaft with regard to axial backlash and
sluggishness.
Adjusting
–Loosen screws at the thread trimmer cam 2.
–Loosen screws at the adjusting ring 3.
–Loosen screws at the bevel gear 4.
–Loosen screws at the bobbin winder wheel 5.
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6 543 2 3

–Loosen screw at the motor coupling 7.
–Push arm shaft cam 6 axially to the right as far as it will go.
–Push adjusting ring 3 against the bearing bush, and tighten screws.
–Check arm shaft with regard to axial backlash and smooth running.
–Tighten screws at the bevel gear 4
(for adjustment, see chapter 2.2).
–Tighten screws at the bobbin winder wheel
(for adjustment, see chapter 2.3).
–Tighten screw at the motor coupling 7
(for adjustment, see chapter 2.6).
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6 543 2 3
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2.4 Bevel gear for the hand wheel
Caution – Risk of injury !
Turnthemainswitchoff.
Check and adjust the bevel gear only when the automatic bartacker is
switched off.
Rule and control
The bevel gear 1 has to be positioned on the upper shaft in such a way
that when the handwheel 2 is engaged and there is as little clearance
as possible between bevel gear 1 and bevel gear 3.
–Engage handwheel 2.
–Check whether there is as little clearance as possible between
bevel gear 1 and bevel gear 3.
Adjusting
–Loosen screws at the bevel gear 1.
–Engage handwheel 2.
–Press bevel gear 1 against the toothed wheel 3 and tighten
fastening screws.
–Turn handwheel and check whether there is as little clearance as
possible between bevel gear 1 and toothed wheel 3.
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2.5 Adjust bobbin winder
Caution – Risk of injury !
Turnthemainswitchoff.
Check and adjust bobbin winder only when the automatic bartacker is
switched off.
Rule:
The bobbin winding operation must stop automatically when the bobbin
is filled up to approx. 0.3 mm below the edge of the bobbin.
Adjustment of the bobbin winder wheel
–Loosen screws at the driver wheel 1.
–Shift driver wheel 1 axially in such a way that it abuts on the bobbin
winder wheel 2 with the bobbin cover screwed on.
–Tighten screws at the driver wheel 1.
The second screw in the direction of rotation is located on the
surface area.
–Put on head cover and tighten.
–Check bobbin winder and repeat adjustment, if necessary.
Adjustment of the bobbin capacity
–Loosen screw 3.
–Adjust bobbin winder clip 4.
–Tighten screw 3.
Note:
When correcting the driver wheel, take care that the oil wicks do not
collide with the driver wheel afterwards.
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2.6 Thread-trimmer cam
Caution – Risk of injury !
Turnthemainswitchoff.
Check and adjust the thread trimmer cam only when the automatic
bartacker is switched off.
Rule and control
The correct position of the thread trimmer cam 1 is marked by a point
on the upper shaft 2 and a line on the thread trimmer cam 1.
The position is correct when both markings are opposite each other.
–Engage handwheel and turn until the marking points 4 and 5 on the
upper shaft and the thread trimmer cam are visible.
–Check that both markings are exactly opposite each other.
Adjusting
–Loosen screws 3 at the thread trimmer cam.
–Twist and axially shift the thread trimmer cam so that both
markings 4 and 5 are exactly opposite each other.
–Tighten screws 3.
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2.7 Crankshaft drive to the hook shaft
Caution – Risk of injury !
Turnthemainswitchoff.
Check and adjust the crankshaft drive only when the automatic
bartacker is switched off.
Rule and control
The arm shaft and the hook shaft are connected by the connecting
rod 4 gripping into the crank 1 of the upper shaft.
The connecting rod 4 and the upper bearing shell 2 have a marking on
one side. When assembling them, the markings must be on the same
side.
Connecting rod 4 and bearing shell 2 must not jam when screwed
together.
–Verify that the markings are on the same side.
–Tighten screws 3 equally.
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2.8 Sewing motor clutch
Caution – Risk of injury !
Turnthemainswitchoff.
Check and adjust sewing motor coupling only when the automatic
bartacker is switched off.
Rule and control
Both clutch halves 1 and 2 must be positioned in such a way that they
abut the knobs of cam 4 on the left or right.
–Rotate arm shaft with the handwheel and check whether the cam
has enough clearance in every position.
Adjusting
–Loosen screw 3 at the coupling.
–Adjust coupling piece 1 on the shaft axially.
–Re-tighten screw 3.
–Check clearance in the coupling.
Note
After the complete removal of the coupling, make sure that the 180°
disc is correctly installed (refer to illustration).
Centre mark should point to the motor.
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2.9 Reference position of the sewing motor
2.9.1 Position of the initiator
Caution – Risk of injury !
Turnthemainswitchoff.
Check and adjust the initiator only when the automatic bartacker is
switched off.
Rule and control
The distance between the initiator 1 and the 180° disc 2 should be kept
as small as possible.
Correction of the distance between the 180° disc and the initiator
–Loosen the screw on the initiator’s clamping piece.
–Adjust the initiator lengthwise so that there is a minimal gap to the
180° disc.
–Turn the machine with the handwheel in order to check that there is
a gap clearance.
–Re-tighten the screw to the clamping piece.
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2.9.2 Adjust reference position
The adjustment of the correct reference position of the sewing motor is
done with the help of the adjusting aid in the control unit.
Invoke adjusting aid
The adjusting aid shows the correct position of crank 1.
–Turn on main switch.
The control unit is initialized.
The main menu appears.
Press function key “F” when the main menu is displayed.
Enter code number “25483”.
Press the “OK”key.
After entry of the correct code number, the display switches to the
menu “Technician mode”.
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Machine
User settings
Service
Free contours
Memory dongle
: ----
1

–Select the “Service” menu using the “ò“key.
–Go to the menu by pressing the “OK” key.
The Service menu appears.
–Select menu “180° disc” with the keys “ñ“or“ò“.
–Start menu with the “OK” key.
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===== 180°-disc =====
Multitest
180°-disc
Events
Init

Adjust 180° disc
–Loosen screw 4 on the coupling and leave the Allen key inserted to
prevent accidental turning.
–Turn crank 1 by hand into the position indicated in the display.
–Tighten screw 4 at the coupling.
–Press the “OK”key.
If the adjustment is correct, the automatic bartacker is positioned in
such a way that the crank 1 is exactly behind the needle bar bush 2.
The following menu appears:
–Check whether the needle bar crank is in the position indicated in
the menu.
–If necessary, change the position of the crank to the position
described above.
Press the “OK”key.
–Then press the “OK” key three times in order to go to the altered
reference position.
–Check whether the crank 1 is parallel to the needle bar bushing 2.
–If necessary, repeat the procedure.
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===== 180°-disc =====
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