DURKOPP ADLER 512-211-01 Operating instructions

Service Instructions
512-211-01
532-211-01
DA_512-211_deen_12-2013.qxd:DA-6-pages.qxd 04.12.2013 12:38 Uhr Seite 3

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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 2016
IMPORTANT
READ CAREFULLY BEFORE USE
KEEP FOR FUTURE REFERENCE

Table of Contents
Service Instructions 512-211-01/532-211-01 - 00.0 - 06/2016 1
1 About this service manual.........................................................5
1.1 Scope of the service manual........................................................5
1.2 Representation conventions – symbols and characters...............5
1.3 Other documents..........................................................................6
1.4 Liability..........................................................................................6
2 Safety information......................................................................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...........................30
8 Adjusting the thread wiper ......................................................32
9 Adjusting the thread regulator................................................33
10 Adjusting the winder................................................................34
10.1 Setting the fill volume .................................................................34
10.2 Adjusting the winding tension.....................................................35
11 Settings via software................................................................36
11.1 Control panel .............................................................................. 36
11.2 Switching on the sewing machine ..............................................37
11.3 Reference the machine ..............................................................37
11.4 Selecting a sewing pattern .........................................................38
11.5 Scaling axes ...............................................................................38
11.5.1 Scaling the X-axis.......................................................................38
11.5.2 Scaling the Y-axis.......................................................................38

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2 Service Instructions 512-211-01/532-211-01 - 00.0 - 06/2016
11.5.3 Converting the buttonhole gap (class 532).................................39
11.5.4 Converting the backtack dimensions (class 512) .......................39
11.6 Setting the speed........................................................................40
11.7 Checking the sewing pattern......................................................40
11.8 Changing the sewing pattern......................................................40
11.9 Winding.......................................................................................41
11.10 Sewing........................................................................................41
11.11 Counter.......................................................................................42
11.12 Interrupting sewing .....................................................................42
11.13 Protecting standard sewing patterns..........................................42
11.14 Storing sewing patterns..............................................................43
11.14.1Mapping memory buttons..........................................................43
11.14.2Sewing with memory buttons.....................................................44
11.14.3Deleting the memory button assignments .................................44
11.15 Storing sewing pattern sequences .............................................44
11.16 Processing sewing pattern sequences.......................................45
11.17 Deleting sewing pattern sequences............................................45
11.18 Stopping sewing ......................................................................... 46
11.19 Editing parameters in the memory..............................................46
11.19.1Editing parameters in level M1 ..................................................46
11.19.2Editing parameters in level M2 ..................................................47
11.20 Resetting parameters to factory settings....................................47
11.21 Editing sewing patterns externally..............................................48
11.22 Working with a USB stick ...........................................................49
11.23 Error messages ..........................................................................51
11.24 Loading software via a USB stick...............................................54
11.24.1Loading the main program.........................................................54
11.24.2Loading sewing patterns............................................................54
11.24.3Setting parameter U085 (class 532)..........................................55
11.24.4Checking the software version...................................................55
12 Service settings via software.................................................. 56
12.1 Basic software operation............................................................56
12.2 Accessing the technician level....................................................57
12.2.1 Editing parameters in level 1......................................................57
12.2.2 Editing parameters in level 2......................................................58
12.3 Setting the blade position...........................................................58
12.4 Loading software via a USB stick...............................................61
12.4.1 Loading the main program..........................................................61
12.4.2 Loading sewing patterns.............................................................61
12.4.3 Setting parameter U085 (class 532)...........................................62
12.4.4 Checking the software version ...................................................62
13 Maintenance..............................................................................63
13.1 Cleaning .....................................................................................63
13.2 Lubrication..................................................................................64
13.2.1 Checking the oil level..................................................................65
13.2.2 Lubricating with grease...............................................................67
13.3 Adjusting the lubrication for the hook .........................................69
14 Appendix ...................................................................................71
14.1 Software error messages ...........................................................71

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Service Instructions 512-211-01/532-211-01 - 00.0 - 06/2016 3
14.2 Circuit diagram ...........................................................................73

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4 Service Instructions 512-211-01/532-211-01 - 00.0 - 06/2016

About this service manual
Service Instructions 512-211-01/532-211-01 - 00.0 - 06/2016 5
1 About this service manual
This manual for the 512/532 sewing machines has beencompiled with the
utmost care. It contains information and notes in order to make long-term
and reliable operation possible.
1.1 Scope of the service manual
This manual describes the setting and maintenance work for sewing ma-
chines 512/532. It applies to all submodels.
The intended use and set-up is described in the operating manual.
1.2 Representation conventions – symbols and characters
Various information in this manual is represented or highlighted by the fol-
lowing characters in order to facilitate easy and quick understanding:
Correct setting
Indicates proper setting.
Malfunctions
Specifies the faults that can occur due to an incorrect setting.
Steps to be performed when operating the machine (sewing and
equipping)
Steps to be performed for servicing, maintenance, and installation
Steps to be performed via the software control panel
The individual steps are numbered:
1. First step
2. Second step
The sequence of the steps must always be followed.
Lists are identified by bullet points.
Result of performing an operation
Change to the machine or in the display.
1.
2.
•


About this service manual
6 Service Instructions 512-211-01/532-211-01 - 00.0 - 06/2016
Important
Special attention must be paid to this point when performing a step.
Information
Additional information, e.g. on alternative operating possibilities.
Observe order
Specifies the work to be performed before or after a setting.
References
 Reference to another section in the manual.
Safety Important warnings for the machine operator are specially designated.
Since safety is of particular importance, hazard symbols, levels of danger
and their signal words are described separately in 3 Safety information.
Orientation If the figure is unclear, indications of "right" and "left" are always from the
operator's point of view.
1.3 Other documents
This equipment 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 these components is descri-
bed in each manufacturer's manual.
1.4 Liability
All information in this operating manual was compiled with consideration
to the state of the art, and applicable standards and regulations.
The manufacturer cannot be held liable for damages resulting from:
• Breakage and transport damages
• Failure to observe operating manual
• Improper use
• Unauthorized modifications to the machine
• Use of untrained personnel
• Use of unapproved replacement parts

Safety information
Service Instructions 512-211-01/532-211-01 - 00.0 - 06/2016 7
2 Safety information
This section contains basic information for your safety.
Read the information carefully before setting up, programming, maintain-
ing or operating the machine.
Make sure to follow the information included in this section. Failure to do
so can result in serious injury and damage to the machine.
2.1 Basic safety instructions
Only authorized personnel should use the machine. Anyone working on
the machine should read the operating manual first.
The machine should only be used in accordance with the manual.
The operating manual should be available at the machine's location at all
times.
Observe the generally applicable safety and accident prevention regula-
tions and the legal regulations concerning industrial safety and environ-
mental protection.
If you are using parts from other suppliers, please also observe the safety
instructions and the operating manual provided by the respective manu-
facturer.
All warnings on the machine must always be in legible condition and may
not be removed. Missing or damaged labels should be replaced immedi-
ately.
In the following situations, the machine must be disconnected from the
power supply using the main switch or by disconnecting the power plug:
• Threading
• Replacing the needle or other sewing tools
• Leaving the workplace
• Performing service work, maintenance work and repairs
Check the machine during use for any externally visible damage. Stop
working as soon as you notice any changes to the machine. Report any
changes to your supervisor. A damaged machine should no longer be
used.
Machines or machine parts that have reached the end of their service life
must not continue to be used. They have to be disposed of correctly and
in accordance with the applicable statutory provisions.
Only qualified specialists may set up the machine. Anyone setting up the
machine must have read the set-up instructions first.

Safety information
8 Service Instructions 512-211-01/532-211-01 - 00.0 - 06/2016
Only qualified specialists may perform maintenance work and repairs.
Anyone maintaining or adjusting the machine must have read the service
manual first.
Safety equipment should not be removed or deactivated. If this cannot be
avoided for a repair operation or service setting, the safety equipment
must be refitted and put back into service immediately afterwards.
Only qualified electrical specialists may perform work on electrical equip-
ment.
The power cable must have a plug authorized for the country in which the
machine is being used. The power plug may only be connected to the
power cable by a qualified specialist.
Work on live components and equipment is prohibited. Exceptions are
defined in the specifications in DIN VDE 0105.
Only use original spare parts from the manufacturer. Missing or faulty
spare parts could impair safety and damage the machine.
2.2 Signal words and symbols used in warnings
Warnings in the text are distinguished by color bars. The color scheme is
oriented towards the severity of the danger. Signal words indicate the de-
gree of risk:
Signal words Signal words and the endangerment that they describe:
Signal word Endangerment
DANGER Will result in serious injury or death.
WARNING Can result in serious injury or death.
CAUTION Can result in minor or moderate injury.
NOTICE Can result in property damage.

Safety information
Service Instructions 512-211-01/532-211-01 - 00.0 - 06/2016 9
Symbols The following symbols indicate the type of risk to personnel:
Examples Examples of the layout of the warnings in the text:
Symbol Type of danger
General risk
Risk of electric shock
Risk of puncturing
Risk of crushing
DANGER
Type and source of risk
Consequences of non-observance
Measures for avoiding the risk
This is what a warning looks like for a hazard that
will result in serious injury or even death if not com-
plied with.
WARNING
Type and source of risk
Consequences of non-observance
Measures for avoiding the risk
This is what a warning looks like for a hazard that
could result in serious injury or even death if not
complied with.

Safety information
10 Service Instructions 512-211-01/532-211-01 - 00.0 - 06/2016
CAUTION
Type and source of risk
Consequences of non-observance
Measures for avoiding the risk
This is what a warning looks like for a hazard that
could result in moderate or minor injury if the warn-
ing is not complied with.
CAUTION
Type and source of risk
Measures for avoiding the risk
This is what a warning looks like for a hazard that
could result in environmental damage if not com-
plied with.
NOTICE
Type and source of danger!
Consequences of non-compliance.
Measures for avoiding the danger.

Work principles
Service Instructions 512-211-01/532-211-01 - 00.0 - 06/2016 11
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.
3.2 Cable routing
Binding the cable
together 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 possible due to incorrect order.
Always adhere to the working order specified in this manual.
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 functionand may cause
damage.
Lay excess cabling as described above.

Work principles
12 Service Instructions 512-211-01/532-211-01 - 00.0 - 06/2016
3.3 Removing the covers
In many types of setting work, you will have to remove the machine covers
first in order to access the components.
Describedhereishow toremovetheindividualcoversandhow toreattach
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
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 functionand 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.
(1) - Machine upper section
①

Work principles
Service Instructions 512-211-01/532-211-01 - 00.0 - 06/2016 13
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
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).
(1) - Screw
(2) - Eye guard (3) - Head cover
①
②
③

Work principles
14 Service Instructions 512-211-01/532-211-01 - 00.0 - 06/2016
3.3.3 Removing and fitting the arm cover
Fig. 3: Removing and fitting the arm cover
Removing the arm cover
1. Loosen all 6 screws (1).
2. Remove the arm cover (2).
Fitting the arm cover
1. Fit the arm cover (2).
2. Tighten all 6 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) - Arm cover
①
②
(1) - Screw (2) - Right-hand side cover
①
②

Work principles
Service Instructions 512-211-01/532-211-01 - 00.0 - 06/2016 15
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
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.
(1) - Screw (2) - Left-hand side cover
①
②

Work principles
16 Service Instructions 512-211-01/532-211-01 - 00.0 - 06/2016
3.3.6 Removing and fitting the rear cover
Fig. 6: Removing and fitting the rear cover
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.
(1) - Screw (2) - Rear cover
①
②

Work principles
Service Instructions 512-211-01/532-211-01 - 00.0 - 06/2016 17
3.3.7 Opening and closing the hook flap
Fig. 7: Opening and closing the 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)
Removing the throat plate
1. Remove both springs of the fabric clamp (1).
(1) - Hook flap
①
(1) - Springs of the fabric clamp
(2) - Clamp feet (3) - Screw (4) - Work surface
①
②
③
④

Work principles
18 Service Instructions 512-211-01/532-211-01 - 00.0 - 06/2016
2. Raise both clamp feet (2).
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)
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)
8. Loosen all 4 screws (8).
9. Remove the throat plate (7) upwards.
(5) - Thread puller blade connecting rod (6) - Screw
(7) - Throat plate (8) - Screw
⑤⑥
⑦⑧