DURKOPP ADLER 991-210-10 Series Operating instructions

911-210-10
Service Instructions

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Property of Dürkopp Adler AG and protected by copyright. Any reuse of these contents,
including extracts, is prohibited without the prior written approval of Dürkopp Adler AG.
Copyright © Dürkopp Adler AG 2020
IMPORTANT
READ CAREFULLY BEFORE USE
KEEP FOR FUTURE REFERENCE

Table of Contents
Service Instructions 911-210-10 - 00.0 - 06/2020 1
1 About these instructions ...........................................................5
1.1 For whom are these instructions intended?..................................5
1.2 Representation conventions – symbols and characters...............5
1.3 Other documents..........................................................................7
1.4 Liability..........................................................................................7
2 Safety...........................................................................................9
2.1 Basic safety instructions...............................................................9
2.2 Signal words and symbols used in warnings..............................10
3 Working basis...........................................................................13
3.1 Order of the adjustments............................................................13
3.2 Laying the cables........................................................................13
3.3 Disassembling and assembling covers.......................................14
3.3.1 Swiveling the machine head up and down.................................14
3.3.2 Disassembling and assembling the arm cover...........................16
3.3.3 Disassembling and assembling the head cover.........................17
3.3.4 Removing and placing the rear cover.........................................18
3.3.5 Removing and placing the toothed belt cover ............................19
3.3.6 Opening and closing the hook cover..........................................20
3.4 Flats on shafts ............................................................................20
3.5 Aligning the machine head.........................................................21
3.6 Locking the machine in place.....................................................25
3.7 Putting the machine into position................................................26
4 Positioning the arm shaft crank..............................................27
5 Positioning the toothed belt wheels.......................................28
5.1 Adjusting the upper toothed belt wheel ......................................28
5.2 Adjusting the lower toothed belt wheel.......................................29
6 Aligning the needle bar linkage...............................................30
7 Position of the hook and needle .............................................31
7.1 Adjusting the looping stroke position..........................................31
7.2 Adjusting the needle bar height..................................................33
7.3 Adjusting the hook side clearance..............................................34
7.4 Adjusting the needle guard.........................................................35
7.5 Adjusting the needle guide.........................................................37
8 Adjusting the bobbin case lifter..............................................38
8.1 Adjusting the lifting gap ..............................................................39
8.2 Adjusting the timing for opening.................................................40
9 Sewing foot lift..........................................................................41
9.1 Adjusting the stroke position drive..............................................41
9.2 Adjusting the light barrier............................................................42
9.3 Adjusting the left stop screw.......................................................43
9.4 Adjusting the sewing foot stroke relative to the needle
bar stroke....................................................................................44
9.5 Adjusting the sewing foot height.................................................45
9.6 Adjusting the reference light barrier sewing axis........................46

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2Service Instructions 911-210-10 - 00.0 - 06/2020
10 Adjusting the needle thread tension.......................................48
10.1 Adjusting the needle thread regulator.........................................48
10.2 Adjusting the thread tensioning spring .......................................49
10.3 Adjusting the thread tension plate ..............................................50
10.4 Calibrating the thread tension plate............................................51
11 Short thread cutter (KFA).........................................................52
11.1 Adjusting thread-pulling knife and control cam...........................53
11.2 Adjusting the locking latch..........................................................54
11.3 Adjusting the thread-pulling knife ...............................................55
11.4 Adjusting the counter blade........................................................56
11.5 Adjusting the cutoff position........................................................58
12 Changing the presser bar........................................................59
12.1 Disassembling the presser bar...................................................59
12.2 Assembling the presser bar........................................................61
13 Checking the machine zero point...........................................63
14 Changing the drives.................................................................64
14.1 Changing the sewing motor........................................................64
14.1.1 Disassembling the sewing motor................................................64
14.1.2 Assembling the sewing motor.....................................................65
14.2 Changing the X drive..................................................................66
14.3 Changing the Y drive..................................................................67
15 Checking the play between toothed rack and gear wheel....68
16 Programming ............................................................................69
16.1 Structure of the software ............................................................70
16.2 Overview of the menu structure..................................................70
16.3 Starting the software...................................................................71
16.4 General operation of the software..............................................74
16.4.1 Entering a password...................................................................74
16.4.2 Closing windows.........................................................................75
16.4.3 Display principles........................................................................75
16.4.4 Scrolling the display....................................................................76
16.4.5 Selecting options from a list........................................................76
16.4.6 Using file filters...........................................................................78
16.4.7 Entering text ...............................................................................79
16.4.8 Entering parameter values .........................................................80
16.4.9 Switching the full-screen display on and off ...............................81
16.4.10Switching zoom on and off.........................................................81
16.5 Opening a seam program or seam sequence for sewing...........82
16.6 Briefly sewing with modified values............................................83
16.6.1 Sewing with a modified thread tension.......................................83
16.6.2 Sewing with a modified speed....................................................84
16.7 Changing the bobbin/managing a thread breaking.....................84
16.7.1 Changing the bobbin ..................................................................85
16.7.2 Bobbin change without a request from the program...................85
16.7.3 Updating the bobbin capacity.....................................................85
16.8 Continuing a seam after an error................................................86
16.8.1 Continuing a seam in Repair mode after an error.......................86

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Service Instructions 911-210-10 - 00.0 - 06/2020 3
16.8.2 Continuing a seam after thread breaking ...................................87
16.9 Resetting the counter .................................................................88
16.10 Seam programs and seam sequences......................................89
16.10.1 Creating a new seam program .................................................89
16.10.2 Performing a contour test .........................................................92
16.10.3 Editing a seam program............................................................93
16.10.4 Creating a new seam sequence.............................................101
16.10.5 Editing a seam sequence .......................................................102
16.10.6 Saving a seam program or seam sequence under a
different name...........................................................................103
16.10.7 Copying a seam program or seam sequence.........................104
16.10.8 Deleting a seam program or seam sequence.........................105
16.11 Editing machine parameters....................................................106
16.12 Checking and changing the technical settings ........................112
16.12.1 Changing the password options .............................................112
16.12.2 Changing the language...........................................................113
16.12.3 Setting date and time..............................................................113
16.12.4 Setting the brightness.............................................................114
16.12.5 Testing the touchscreen .........................................................114
16.13 Testing the functions of the machine.......................................115
16.13.1 Testing inputs and outputs......................................................115
16.13.2 Adjusting the stroke position...................................................117
16.13.3 Testing the sewing motor........................................................118
16.13.4 Calling up log displays and error lists.....................................119
16.14 Initializing the control and performing updates........................120
16.14.1 Initializing the control..............................................................121
16.14.2Initializing the control panel .....................................................121
16.14.3Performing an update of the control ........................................121
16.15 DA CAD professional...............................................................122
17 Maintenance............................................................................123
17.1 Cleaning ...................................................................................124
17.1.1 Cleaning the machine...............................................................124
17.1.2 Cleaning the motor fan mesh ...................................................125
17.2 Lubricating................................................................................126
17.2.1 Lubricating the machine head ..................................................127
17.2.2 Lubricating the hook .................................................................128
17.3 Servicing the pneumatic system...............................................129
17.3.1 Adjusting the operating pressure..............................................129
17.3.2 Draining the water-oil mixture...................................................130
17.3.3 Cleaning the filter element........................................................131
17.4 Servicing specific components .................................................132
17.5 Parts list....................................................................................132
18 Decommissioning...................................................................133
19 Disposal...................................................................................135
20 Troubleshooting .....................................................................137
20.1 Customer Service.....................................................................137
20.2 Messages of the software.........................................................137
20.3 Errors in sewing process ..........................................................142

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4Service Instructions 911-210-10 - 00.0 - 06/2020
21 Technical data.........................................................................145
21.1 Data and characteristic values .................................................145
21.2 Requirements for fault-free operation.......................................146

About these instructions
Service Instructions 911-210-10 - 00.0 - 06/2020 5
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 (p. 137).
Consider these instructions as part of the product and keep it easily
accessible.
1.1 For whom are these instructions intended?
These instructions are intended for:
• Specialists:
This group has the appropriate technical training for performing
maintenance or repairing malfunctions.
With regard to minimum qualification and other requirements to be met
by personnel, please also follow the chapter Safety (p. 9).
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 adjustment.
Cover
Specifies which covers must be disassembled in order to access the
components to be set.

About these instructions
6Service Instructions 911-210-10 - 00.0 - 06/2020
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.
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 an adjustment.
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 (p. 9).
Location
information If no other clear location informationis used in a figure, indications of right
or left are always from the user's point of view.
1.
2.
…
•


About these instructions
Service Instructions 911-210-10 - 00.0 - 06/2020 7
1.3 Other documents
The machine includes components from other manufacturers. Each man-
ufacturer has performed a hazard assessment for these purchased parts
and confirmed their design compliance with applicable European and na-
tional regulations. The proper use of the built-in components is described
in the corresponding manufacturer's 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:
• Breakage and transport damages
• Failure to observe these instructions
• Improper use
• Unauthorized modifications to the machine
• Use of untrained personnel
• Use of unapproved parts
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.
Leave machines, equipment and packaging material in the condition in
which they were found when the damagewasdiscovered. This will ensure
any claims against the transport company.
Report all other complaints to Dürkopp Adler immediately after receiving
the product.

About these instructions
8Service Instructions 911-210-10 - 00.0 - 06/2020

Safety
Service Instructions 911-210-10 - 00.0 - 06/2020 9
2 Safety
This chapter contains basic information for your safety. Read the instruc-
tions carefully before setting up or operating the machine. 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 locationat 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 Usealiftingcarriageorstackertotransport themachine.Raise themachine
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 thelegal regulationsconcerning industrialsafety andtheprotectionof
the environment.
Allthe warningsand safetysigns onthemachinemust alwaysbe inlegible
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 be used for:
• Setting up the machine/putting the machine into operation
• Performing maintenance work and repairs
• Performing work on electrical equipment
Only authorized persons may work on the machine and must first have
understood these instructions.

Safety
10 Service Instructions 911-210-10 - 00.0 - 06/2020
Operation Check the machine during operating for any externally visible damage.
Stop working if you notice any changes to the machine. Report any chang-
es to your supervisor. Do not use a damaged machine any further.
Safety
equipment Safety equipment should not be disassembled or deactivated. If it is essen-
tial to disassemble 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:
Symbols The following symbols indicate the type of danger to personnel:
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
Symbol Type of danger
General
Electric shock

Safety
Service Instructions 911-210-10 - 00.0 - 06/2020 11
Examples Examples of the layout of 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
serious or even fatal injury if ignored.
This is what a warning looks like for a hazard that could result in
moderate or minor injury if the warning is ignored.
Puncture
Crushing
Environmental damage
Symbol Type of danger
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.

Safety
12 Service Instructions 911-210-10 - 00.0 - 06/2020
This is what a warning looks like for a hazard that could result in
environmental damage if ignored.
This is what a warning looks like for a hazard that could result in
property damage if ignored.
CAUTION
Type and source of danger!
Consequences of non-compliance.
Measures for avoiding the danger.
NOTICE
Type and source of danger!
Consequences of non-compliance.
Measures for avoiding the danger.

Working basis
Service Instructions 911-210-10 - 00.0 - 06/2020 13
3 Working basis
3.1 Order of the adjustments
Order
The setting positions for the machine are interdependent.
Always comply with the order of individual adjustment steps as specified.
It is absolutely essential that you follow all notices regarding prerequisites
and subsequent settings that are marked with in the margin.
3.2 Laying the cables
To lay the cables:
1. Lay any excess cables neatly in proper cable snakes.
2. Bind together the cable loops with cable ties.
Important
Tie loops wherever possible to fixed parts.
The cables must be secured firmly.
3. Cut off any overlapping cable ties.
NOTICE
Property damage may occur!
Risk of machine damage from incorrect order.
It is essential to follow the working order specified in these
instructions.
NOTICE
Property damage may occur!
Excess cables can impair the functioning of moving
machine parts. This impairs the sewing function and can result in
damage.
Lay excess cables as described.

Working basis
14 Service Instructions 911-210-10 - 00.0 - 06/2020
3.3 Disassembling and assembling covers
For many types of adjustment work, you will have to remove the machine
covers first in order to access the components.
This chapter describes how to remove and then assemble the individual
coversagain.Thetext foreachtypeofadjustmentworkthenspecifiesonly
the cover that needs to be removed at that particular time.
3.3.1 Swiveling the machine head up and down
Cover
To access the components on the underside of the machine, swivel up
the machine head.
WARNING
Risk of injury from moving parts!
Crushing possible.
Switch off the machine before removing or
re-assembling covers.
NOTICE
Property damage may occur!
Risk of machine damage from falling machine head.
When swiveling down the machine head, hold the machine head in
place until it has returned to its position.

Working basis
Service Instructions 911-210-10 - 00.0 - 06/2020 15
Fig. 1: Swiveling the machine head up and down
Swiveling up the machine head
Important
The transport carriage must be at the rear.
To swivel up the machine head:
1. Release the locking lever (3) under the tabletop.
2. Liftthemachineheadintheheadcoverarea(1)andswivelupcarefully.
3. The latch (2) latches into place.
The space under the stand is now accessible.
Swiveling down the machine head
To swivel down the machine head:
1. Hold the machine head in the head cover area (1).
2. Release the latch (2).
3. Swivel down the machine head carefully.
4. Latch the locking lever (3) under the tabletop.
(1) - Head cover
(2) - Latch (3) - Locking lever
①
②
③

Working basis
16 Service Instructions 911-210-10 - 00.0 - 06/2020
3.3.2 Disassembling and assembling the arm cover
Fig. 2: Disassembling and assembling the arm cover
Disassembling the arm cover
To disassemble the arm cover:
1. Unscrew the motor cover (1).
2. Loosen screws (2) and countersunk screw (3).
3. Disassemble the arm cover (4).
Assembling the arm cover
To assemble the arm cover:
1. Assemble the arm cover (4).
2. Tighten the countersunk screw (3).
3. Tighten the screws (2).
4. Press down the hand crank (5) and check for ease of movement.
If necessary, adjust the arm cover position.
The hand crank (5) must disengage.
5. Tighten the screws for the motor cover (1).
(1) - Motor cover
(2) - Screws
(3) - Countersunk screw
(4) - Arm cover
(5) - Hand crank
②
④① ⑤
③

Working basis
Service Instructions 911-210-10 - 00.0 - 06/2020 17
3.3.3 Disassembling and assembling the head cover
Fig. 3: Disassembling and assembling the head cover
Disassembling the head cover
To disassemble the head cover:
1. Loosen the screws (1).
2. Disassemble the head cover (2).
Assembling the head cover
To assemble the head cover:
1. Assemble the head cover (2).
2. Tighten the screws (1).
(1) - Screws (2) - Head cover
①②

Working basis
18 Service Instructions 911-210-10 - 00.0 - 06/2020
3.3.4 Removing and placing the rear cover
Fig. 4: Removing and placing the rear cover
Removing the rear cover
To remove the rear cover:
1. Loosen the screws (1).
2. Remove the rear cover (2).
Placing the rear cover
To place the rear cover:
1. Place the rear cover (2).
2. Tighten the screws (1).
(1) - Screws (2) - Rear cover
①
②