DURKOPP ADLER 911-211 Operating instructions

911-211
Service Instructions

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Property of Dürkopp Adler AG and protected by copyright. Any reuse of these contents, i
ncluding extracts, is prohibited without the prior written approval of Dürkopp Adler AG.
Copyright © Dürkopp Adler AG - 2015
IMPORTANT
READ CAREFULLY BEFORE USE
KEEP FOR FUTURE REFERENCE

Contents
Service Instructions 911-211 - 00.0 - 02/2015 1
1 About these Service Instructions.............................................. 3
1.1 Scope of the Service Instructions ................................................. 3
1.2 Representation conventions – symbols and characters ............... 3
1.3 Other documents .......................................................................... 4
1.4 Liability.......................................................................................... 4
2 Safety........................................................................................... 5
2.1 Basic safety instructions ............................................................... 5
2.2 Signal words and symbols used in warnings................................ 6
3 Working basis ............................................................................. 9
3.1 Sequence of the settings .............................................................. 9
3.2 Cable routing ................................................................................ 9
3.3 Removing and opening covers ................................................... 10
3.3.1 Access to the machine bottom section ....................................... 10
3.3.2 Removing and installing the motor cover.................................... 11
3.3.3 Removing and installing the arm cover....................................... 11
3.3.4 Removing and installing the head cover..................................... 12
3.3.5 Removing and installing the rear cover ...................................... 12
3.3.6 Removing and installing the belt cover....................................... 13
3.3.7 Opening and closing the bobbin flap .......................................... 13
3.3.8 Removing and fitting the sliding plate......................................... 14
3.4 Removing and installing the burner cover (optional) .................. 14
3.5 Flats on shafts ............................................................................ 15
3.6 Putting the machine into position................................................ 15
3.7 Locking the sewing machine in place ......................................... 16
4 Machine head............................................................................ 17
4.1 Positioning the arm shaft crank .................................................. 17
4.2 Positioning the toothed belt pulleys ............................................ 18
4.2.1 Upper toothed belt pulley............................................................ 18
4.2.2 Lower toothed belt pulley............................................................ 19
4.3 Aligning the needle bar linkage .................................................. 20
4.4 Position of the hook and needle ................................................. 21
4.4.1 Setting the loop stroke position .................................................. 21
4.4.2 Setting the needle bar height...................................................... 22
4.4.3 Setting the hook side clearance ................................................. 24
4.4.4 Adjusting the needle guard......................................................... 25
4.4.5 Setting the needle guide............................................................. 27
4.5 Setting the bobbin housing lifter ................................................. 28
4.5.1 Setting the lifting gap .................................................................. 28
4.5.2 Setting the timing for opening..................................................... 29
4.6 Sewing foot lifter ......................................................................... 31
4.6.1 Setting the stroke position drive ................................................. 31
4.6.2 Setting the light barrier ............................................................... 32
4.6.3 Setting the left stop screw .......................................................... 34
4.6.4 Setting the foot stroke to the needle stroke ................................ 35
4.6.5 Setting the presser foot height.................................................... 36
4.6.6 Setting the reference light barrier sewing axis............................ 38
4.7 Setting the needle thread tension............................................... 39
4.7.1 Setting the thread regulator ........................................................ 39
4.7.2 Setting the thread tensioning spring ........................................... 40

Contents
Service Instructions 911-211 - 00.0 - 02/2015
2
4.7.3 Adjusting the thread tension ....................................................... 41
4.8 Thread cutter .............................................................................. 43
4.8.1 Setting the height of the thread-pulling knife .............................. 43
4.8.2 Setting the cutoff curve............................................................... 44
4.8.3 Setting the cutting pressure........................................................ 45
4.8.4 Setting point in time for cutting ................................................... 47
4.9 Thread burner (optional)............................................................. 48
4.9.1 Adjusting the upper burner ......................................................... 48
4.9.2 Adjusting the lower burner.......................................................... 53
4.9.3 Changing the burner tips ............................................................ 54
4.9.4 Adjusting the thread advancing device....................................... 55
4.9.5 Setting the hook thread clamp.................................................... 57
4.9.6 Setting the control cam for the thread advancing device............ 58
4.10 Changing the material presser foot bar ...................................... 59
5 Sewing machine ....................................................................... 61
5.1 Checking the machine zero point ............................................... 61
5.2 Changing the drives.................................................................... 62
5.2.1 X drive ........................................................................................ 62
5.2.2 Y drive ........................................................................................ 63
5.3 Checking the play between the toothed rack and
gear pinion.................................................................................. 64
6 Maintenance work .................................................................... 65
6.1 Lubrication .................................................................................. 65
6.1.1 Lubrication - machine head ........................................................ 66
6.1.2 Lubrication - hook ....................................................................... 67
6.2 Thread suction device ................................................................ 68
6.3 Pneumatic system ...................................................................... 68
6.3.1 Setting operating pressure ......................................................... 68
6.3.2 Draining the water condensation ................................................ 69
6.3.3 Cleaning the filter element.......................................................... 70
6.4 Cleaning work............................................................................. 71
6.4.1 Cleaning the machine................................................................. 71
6.4.2 Cleaning the motor fan mesh ..................................................... 72
6.5 Checking the toothed belt........................................................... 72

About these Service Instructions
Service Instructions 911-211 - 00.0 - 02/2015 3
1 About these Service Instructions
These instructions for the CNC sewing unit 911-211 were compiled with
the utmost care. They contain information and notes in order to ensure
long-term and reliable operation.
1.1 Scope of the Service Instructions
These instructions describe the setting and maintenance work on the
911-211 CNC sewing unit. They apply to all submodels.
The intended use and setup is described in the Operating Instructions.
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 under-
standing:
Proper 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 service, 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.
Important
Special attention must be paid to this point when performing a step.
1.
2.
etc
•


About these Service Instructions
Service Instructions 911-211 - 00.0 - 02/2015
4
Information
Additional information, e.g. on alternative operating options.
Sequence
Specifies the work to be performed before or after a setting.
References
 Reference to another section in these instructions.
Safety Important warnings for the machine users are specially designated. Since
safety is of particular importance, hazard symbols, levels of danger and
their signal words are described separately in 2 Safety, p. 5.
Orientation If the figure is unclear, indications of "right" and "left" are always from the
user's point of view.
1.3 Other documents
Some of the machine's built-in components have been made by third-party
manufacturers. Each manufacturer has performed a hazard assessment
for these purchased parts and confirmed their design compliance with ap-
plicable European and national regulations. The proper use of these com-
ponents is described in the instructions prepared by each manufacturer.
1.4 Liability
All information in these service instructions was compiled with consider-
ation to the state of the art, and applicable standards and regulations.
The manufacturer cannot be held liable for damages resulting from:
• Breakage and damage during transport
• Failure to follow the operating instructions
• Improper use
• Unauthorized modifications to the machine
• Use of untrained personnel
• Use of unapproved replacement parts

Safety
Service Instructions 911-211 - 00.0 - 02/2015 5
2 Safety
This chapter contains basic information for your safety. Read the instruc-
tions carefully before setting up 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
The machine may only be used as described in these instructions.
The instructions should be available at the machine's location at all times.
Work on live components and equipment is prohibited. Exceptions are
defined in the regulations set forth in DIN VDE 0105.
For the following work, the machine must be disconnected from the power
supply using the main switch or by disconnecting the power plug:
• Replacing the needle or other sewing tools
• Leaving the workplace
• Performing maintenance work and repairs
• Threading
Missing or faulty spare parts could impair safety and damage the machine.
Make sure you only use original replacement parts from the manufacturer.
Transport Use a sturdy lifting carriage or stacker for transporting the machine. Raise
the machine max. 20 mm and secure it against slipping off.
Setup 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.
Obligations
of the operator
Observe the country-specific safety and accident prevention regulations
and the legal regulations concerning industrial safety and the protection of
the environment.
All warnings and safety signs on the machine must always be in legible
condition and may not be removed. Missing or damaged labels should be
replaced immediately.
Requirements
to be met by
the personnel
The machine may only be set up by qualified technicians.
Maintenance work and repairs may only be carried out by qualified tech-
nicians.
Work on electrical equipment may only be carried out by qualified special-
ists.
Only authorized persons may work on the machine. Every person who
works on the machine must first have understood these instructions.

Safety
6Service Instructions 911-211 - 00.0 - 02/2015
Operation Inspect the machine while in use for any externally visible damage. Stop
working if you notice any changes to the machine. Report any changes to
your supervisor. A damaged machine must no longer be used.
Safety
equipment
Safety equipment should not be removed or deactivated. If this cannot be
avoided for a repair operation, the safety equipment must be refitted and
put back into service immediately afterwards.
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
severity of the danger.
Signal words Signal words and the hazard that they describe:
Symbols The following symbols indicate the type of danger to personnel:
Signal word Meaning
DANGER (with hazard symbol)
If ignored, death or serious injury will result
WARNING (with hazard symbol)
If ignored, death or serious injury can result
CAUTION (with hazard symbol)
If ignored, moderate or light injury can result
NOTICE (without hazard symbol)
If ignored, material damage can result
Symbol Type of danger
General
Electric shock
Pointed objects
Crushing
Environmental damage

Safety
Service Instructions 911-211 - 00.0 - 02/2015 7
Examples Examples of the layout of the warnings in the text:
This is what a warning looks like for a hazard that will result in serious
injury or even death if ignored.
This is what a warning looks like for a hazard that could result in seri-
ous injury or even death if ignored.
This is what a warning looks like for a hazard that could result in mod-
erate or minor injury if the warning is ignored.
This is a warning note for a hazard that could result in environmental
damage if ignored.
DANGER
Type and source of danger!
Consequences of non-compliance.
Measures for avoiding the danger.
WARNING
Type and source of danger!
Consequences of non-compliance.
Measures for avoiding the danger.
CAUTION
Type and source of danger!
Consequences of non-compliance.
Measures for avoiding the danger.
CAUTION
Type and source of danger!
Consequences of non-compliance.
Measures for avoiding the danger.

Safety
8Service Instructions 911-211 - 00.0 - 02/2015
This is what a warning looks like for a hazard that could result in mate-
rial damage if ignored.
NOTICE
Type and source of danger!
Consequences of non-compliance.
Measures for avoiding the danger.

Working basis
Service Instructions 911-211 - 00.0 - 02/2015 9
3 Working basis
3.1 Sequence of the settings
Sequence
must be
observed!
The setting positions for the sewing machine are interdependent.
Always adhere to the specified sequence for the individual setting steps.
Always observe all information on requirements and following settings
marked at the side with .
3.2 Cable routing
Tying cables
together
Lay all cables in the machine such that moving parts are not impaired in
their ability to function correctly.
1. Lay any excess cabling 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
Machine damage possible due to incorrect sequence.
It is essential to adhere to the working sequence specified in these
instructions.
NOTICE
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.

Working basis
10 Service Instructions 911-211 - 00.0 - 02/2015
3.3 Removing and opening covers
In many types of setting work, you will have to remove the machine covers
in order to access the components.
Described here is how to remove the individual covers and how to refit
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 swivel up the machine head.
Fig. 1: Swiveling the machine head up and down
Swiveling up the machine head
1. Release the locking lever (1) under the table top.
2. Lift the machine head in the head cover area (2) and swivel up carefully.
The latch (4) latches into place.
Swiveling down the machine head
1. Hold the machine head in the head cover area (2).
2. Release the latch (4).
3. Swivel the machine head down.
4. Latch the locking lever (1) under the table top.
WARNING
Risk of injury!
Crushing injuries from moving parts.
Switch the machine off before you remove the
covers or refit them.
(1) - Locking lever
(2) - Head cover area
(3) - Drive carriage
(4) - Latch
③④
①②

Working basis
Service Instructions 911-211 - 00.0 - 02/2015 11
3.3.2 Removing and installing the motor cover
Fig. 2: Removing and installing the motor cover
Removing the motor cover
1. Loosen both screws (1).
2. Remove the motor cover (2).
Installing the motor cover
1. Fit the motor cover (2).
2. Tighten both screws (1).
3.3.3 Removing and installing the arm cover
Fig. 3: Removing and installing the arm cover
Removing the arm cover
1. Remove the motor cover.
2. Loosen the screws (1).
3. Remove the arm cover (2).
Installing the arm cover
1. Fit the arm cover (2).
2. Tighten the screws (1).
3. Press the hand crank and check for ease of movement; adjust the arm
cover position if necessary.
4. Fit the motor cover.
(1) - Screws (2) - Motor cover
②
①
(1) - Screws (2) - Arm cover
②
①

Working basis
12 Service Instructions 911-211 - 00.0 - 02/2015
3.3.4 Removing and installing the head cover
Fig. 4: Removing and installing the head cover
Removing the head cover
1. Loosen the screws (1).
2. Remove the head cover (2).
Installing the head cover
1. Fit the head cover (2).
2. Tighten the screws (1).
3.3.5 Removing and installing the rear cover
Fig. 5: Removing and installing the rear cover
Removing the rear cover
1. Undo all 3 screws (1).
2. Take off the rear cover (2) by moving it back.
Installing the rear cover
1. Fit the rear cover (2).
2. Tighten all 3 screws (1).
(1) - Screws (2) - Head cover
①
②
(1) - Screws (2) - Rear cover
①
②

Working basis
Service Instructions 911-211 - 00.0 - 02/2015 13
3.3.6 Removing and installing the belt cover
Fig. 6: Removing and installing the belt cover
Removing the belt cover
1. Undo all 3 screws (1).
2. Take off the belt cover (2).
Installing the belt cover
1. Fit the belt cover (2).
2. Tighten all 3 screws (1).
3.3.7 Opening and closing the bobbin flap
Fig. 7: Opening and closing the bobbin flap
Opening the bobbin flap
1. Switch the machine on and reference it.
2. Remove the material holder.
3. Press the Safe Stop key.
The bobbin flap (1) pivots to the side.
(1) - Screws (2) - Belt cover
①
②
(1) - Bobbin flap
①

Working basis
14 Service Instructions 911-211 - 00.0 - 02/2015
Closing the bobbin flap
1. Release the Safe Stop key.
2. Fit the material holder.
3.3.8 Removing and fitting the sliding plate
Fig. 8: Removing and fitting the sliding plate
Removing the sliding plate
1. Reach through the hole (2) from below and lift the sliding plate (1).
2. Remove the sliding plate (1).
Fitting the sliding plate
1. Fit the sliding plate (1).
3.4 Removing and installing the burner cover (optional)
Fig. 9: Removing and installing the burner cover
(1) - Sliding plate (2) - Hole
①
②
(1) - Screws (2) - Burner cover
①
②

Working basis
Service Instructions 911-211 - 00.0 - 02/2015 15
Removing the burner cover
1. Loosen both screws (1).
2. Remove the burner cover (2).
Installing the burner cover
1. Fit the burner cover (2).
2. Tighten both screws (1).
3.5 Flats on shafts
Fig. 10: Flats on shafts
Some shafts have flats at those points where the components are
clamped on to the shaft. This stabilizes the connection and makes adjust-
ment easier.
Always make sure that the whole screw is seated flush on the flat.
3.6 Putting the machine into position
For some settings, the machine must be put into a certain position, using
the hand crank on the arm cover. The machine has no handwheel.
Fig. 11: Hand crank
Setting steps
1. Press and turn the hand crank (1) until the machine is in the setting
position.
2
1
(1) - Flat (2) - Shaft
(1) - Hand crank
①

Working basis
16 Service Instructions 911-211 - 00.0 - 02/2015
3.7 Locking the sewing machine in place
For some settings, the machine has to be locked in place. To do this, the
arresting pin from the accessory pack is inserted into a groove on the arm
shaft crank to block the arm shaft.
Fig. 12: Arresting pin and arresting grooves on the arm shaft crank
There are 2 securing positions:
•Position 1: Loop stroke position
• 5 mm end in the large groove
• Setting the loop stroke and needle bar height
•Position 2: Needle at top dead center
• 3 mm end in the small groove
• Checking the top dead center of the needle bar
Fig. 13: Locking the sewing machine in place
Locking the machine in place
1. Insert the arresting pin (6) with the appropriate end in the groove (5).
Removing the lock
1. Pull the arresting pin (6) out of the groove (5).
(1) - Arresting pin
(2) - Large arresting groove
(3) - Small arresting groove
(4) - Arm shaft crank
①
②
③
④
(5) - Groove (6) - Arresting pin
⑤
⑥

Machine head
Service Instructions 911-211 - 00.0 - 02/2015 17
4 Machine head
4.1 Positioning the arm shaft crank
Proper setting
The 3 setscrews (2) on the arm shaft crank (1) are seated flush on the flat.
Cover
• Arm cover (
 3.3.2 Removing and installing the motor cover, p. 11)
Fig. 14: Setting the arm shaft crank
Setting steps
1. Release all the setscrews (2) on the arm shaft crank (1).
2. Turn the arm shaft crank (1) such that the setscrews (2) are seated flush
on the flat of the arm shaft.
3. Push the arm shaft crank (1) to the right as far as it will go.
4. Tighten all the setscrews (2) on the arm shaft crank (1).
WARNING
Risk of injury!
Crushing injuries from moving parts.
Switch the machine off before you check and set
the position of the arm shaft crank.
(1) - Arm shaft crank (2) - Setscrews
①
②

Machine head
18 Service Instructions 911-211 - 00.0 - 02/2015
4.2 Positioning the toothed belt pulleys
The two toothed belt pulleys must be positioned relative to each other
such that the toothed belt can run correctly.
Sequence
• Always check the position of the other toothed belt pulley after making a
change on either of the toothed belt pulleys.
4.2.1 Upper toothed belt pulley
Proper setting
The 2 setscrews for the upper toothed belt pulley are seated flush on the
flat.
Cover
• Arm cover (
 3.3.2 Removing and installing the motor cover, p. 11)
Fig. 15: Setting the upper toothed belt pulley
Setting steps
1. Using the screwdriver, push the toothed belt (4) sufficiently far to the
side that the 2 setscrews (1) can be reached.
2. Loosen the setscrews (1).
3. Turn the upper toothed belt pulley (3) such that the setscrews (1) are
seated flush on the flat (2) of the arm shaft.
4. Tighten the setscrews (1).
5. Use the screwdriver to push the toothed belt (4) back again.
WARNING
Risk of injury!
Crushing injuries from moving parts.
Switch the machine off before you check and set
the upper toothed belt pulley.
(1) - Setscrews
(2) - Flat on the arm shaft
(3) - Upper toothed belt pulley
(4) - Toothed belt
③
④
①
②