Duerkopp Adler 525 Operating Instruction

Instruction manual

525

Minerva Boskovice, a.s., Sokolská 60, CZ - 680 17 Boskovice Tel.: +420-516-453434, 453433, 494111 Fax: +420-516-452165 http://www.minerva-boskovice.com

Edition : 01/2004 Printed: Czech Republic

Contents - part A - Instruction manual:

1. Proper use of the machine .................................................................................................................................................. 1

2. Description of the machine ................................................................................................................................................. 1

3. Machine subclasses ............................................................................................................................................................ 1

4. Survey of equipment ............................................................................................................................................................ 1

4.1 -for the subclass -101 ............................................................................................................................................... 1

4.1.1 Necessary equipment ..................................................................................................................................... 1

4.1.2 Sewing equipment.......................................................................................................................................... 1

4.1.3 Optional equipment ........................................................................................................................................ 2

4.2 -for the subclass -105 ............................................................................................................................................... 2

4.2.1 Necessary equipment ..................................................................................................................................... 2

4.2.2 Sewing equipment.......................................................................................................................................... 2

4.2.3 Optional equipment ........................................................................................................................................ 2

5. Technical data ..................................................................................................................................................................... 3

Table 2 ........................................................................................................................................................................ 4,5

6. Operation of the machine .................................................................................................................................................... 6

6.1 Upper thread threading ............................................................................................................................................ 6

6.2 Winding of thread on the hook bobbin ................................................................................................................... 6

6.3 Needle insertion ....................................................................................................................................................... 6

6.4 Adjustment of the upper thread tension ................................................................................................................. 7

6.5 Change of the hook bobbin, threading and setting of the bottom thread tension .............................................. 7

6.6 Adjustment of the stitch length, reverse stitching ................................................................................................. 8

6.7 Adjustment of the pattern width .............................................................................................................................. 8

6.8 Regulation of the presser foot pressure, presser foot lifting ................................................................................ 8

7. Machine maintenance ......................................................................................................................................................... 9

7.1 Cleaning .................................................................................................................................................................... 9

7.2 Lubrication ............................................................................................................................................................... 9

8. Electronic control of the machine ...................................................................................................................................... 10

8.1 Control of sewing by means of control elements ................................................................................................... 10

8.1.1 Via treadle ....................................................................................................................................................... 10

8.1.2 Via pushbutton ............................................................................................................................................... 10

8.1.3 Via control panel Efka V 810/V 820 ................................................................................................................ 10

8.2 Adjustment of automatic functions via control panel for stop motor ................................................................... 11

8.2.1 By using stop motor Efka with panel V 810 ................................................................................................... 11

8.2.1.1 Adjustment by means of buttons with fixed setting function ........................................................... 11

8.2.1.2 Setting by means of parameters ......................................................................................................... 12

8.2.2 By using stop motor Efka with panel V 820 ................................................................................................... 13

8.2.2.1 Adjustment by means of buttons with fixed setting function ........................................................... 14

8.2.2.2 Setting by means of parameters ......................................................................................................... 14

Operating instructions for eventual trouble shooting ....................................................................................................... 16

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 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 tread-ing, 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 the machine must be disconnected from the compressed air supply system.

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.

It is absolutely necessary to respect the safety instructions marked by these signs.

Danger of bodily injuries !

Please note also the general safety instructions.

IMPORTANT WARNING!

To the feeding network cord, it is necessary to connect the respective network plug which has been approved in the country

of utilizing the machine. This operation should be performed by a worker acquainted with the electric safety rules being in

force in the given country. The supplier is not responsible for any damages caused by defective plug or owing to incorrect

assembly of the plug.

In spite of all safety measures made on the machines, inappropriate actions of the operator may lead to dangerous situations. In

industrial sewing machines, attention should be paid to the following still remaining possible sources of injury:

1. Moving sewing needle

- risk of injury when sewing with raised pressure foot or top roller, because the finger guard is then positioned too high.

2. Moving thread take-up lever

- risk of injury when inadvertently or intentionally inserting the finger(s) between the thread take-up lever and its guard.

3. Moving pressure member

- risk of injury when holding sewn work in immediate vicinity of the pressure member and beginning to insert under the pressure

member a considerably thicker sewn work portion,

- risk of injury when sinking the pressure member.

4. When switched off, the clutch motor slows down by inertia but would be reactivated by an accidental tread-ing down of the motor

treadle. To avoid such risk, it is advised to hold the handwheel by hand and slightly to depress the motor treadle.

Part A - Instruction manual

1. Proper use of the machine

The machine is designed for decorative (figure) stiching in manufacture of outwear and of ladies´ underwear of elastic materials (lycra). It can be used for decorative stitching of canvas footwear as well. In general, only dry material may be sewn on these machines, which should not be thicker than 4 mm when being compressed by the presser foot. The material should not contain any hard objects, because in such opposite case the sewing operation would be possible only with an eye protector. Such eye protector is not supplied for the time being. When sewing very hard or compact materials with a thicker needle, the total thickness thereof is limited. In such case it is also necessary to reduce substantially the sewing speed below the value quoted in the par. 5. These machines may be installed and operated only in dry and maintained rooms. As manufacturers of industrial sewing machines we start from the supposition that our machines will be operated at least by a trained staff, so that all usual operating activities and their eventual risks may be supposed to be known.

Machine noisiness

The noisiness of machines is measured according to ISO 3746, ISO 11204 at the maximum sewing speed. Laeq = equivalent noise level of the machine itself on the working place converted in % of the machine utilization (dB) – is given

in the following table

Type of the Noisiness % machine

machine dB employment

525-101 84 20

525-105 84 20

2. Description of the machine

Industrial flat-bed sewing machine for figure stitching of patterns formed by one or two needles. It stitches using a two-thread lockstitch, with two-way drop feed. The stitch length is adjustable by means of a knob mounted on the web of the machine arm. The backward stitching is controlled by a hand lever, eventually, by pedal or by electromagnet in accordance with the equipment of the machine. The shape of the stitched pattern is given by an exchangeable cam, always for one pattern – table 2. The presser foot lifting is controlled by a hand lever, eventually, by pedal, or by a knee lever or by electromagnet in accordance with the machine equipment. The machine is provided with a large diameter horizontal hook. It has a 1.8 x greater reserve (volume) of threads than a standard hook. The lubricating system of the machine is of a group wick-feed type with automatic regreasing of the hook.

3. Machine subclasses

Table 1

Machine type Hook Presser foot lifting Backtacking Thread

trimmer

Class-subclass Large Via knee lever Via electro- Via hand Via Via electro-

or pedal magnet lever pedal magnet

525-101

525-105

standard equipment

•

optional equipment

•

4. Survey of equipment

This survey does not include the equipment assembled on the stand (see part B).

4.1 -for the subclass -101

4.1.1 Necessary equipment

S791 995068 Parts of backtacking (with pedal) S791 642049 Cam for decorative stitching - standard S791 642037 Adjusting cam – plain stitch

4.1.2 Sewing equipment

S791 124032 35 Sewing equipment 525 E 032 - standard S791 124033 35 Sewing equipment 525 E 033 S791 124034 35 Sewing equipment 525 E 034 S791 224075 35 Sewing equipment 525 E 075

4.1.3 Optional equipment

S791 149001 Attachment for serging operation S791 235002 Unwinding device S791 224074 Throat plate 811768 (for stitching fine materials) S791 400023 Guiding for stitching together S791 630002 Equipment for stitching with two needles S791 642038 Cam for decorative stitching S791 642039 Cam for decorative stitching S791 642040 Cam for decorative stitching S791 642041 Cam for decorative stitching S791 642042 Cam for decorative stitching S791 642043 Cam for decorative stitching S791 642044 Cam for decorative stitching S791 642045 Cam for decorative stitching S791 642046 Cam for decorative stitching S791 642047 Cam for decorative stitching S791 642048 Cam for decorative stitching S791 642050 Cam for decorative stitching S791 642051 Cam for decorative stitching S791 642052 Cam for decorative stitching S791 642053 Cam for decorative stitching S791 642055 Cam for decorative stitching S791 151016 Hinged foot with front thread slit - zig-zag stitch width 6 mm S791 151017 Hinged foot with front thread slit - zig-zag stitch width 10 mm S791 947001 Adjustment gauges S794 222012 Sewing lamp S741 610118 40 High mortality spare parts kit in a plastics box

4.2 -for the subclass - 105

4.2.1 Necessary equipment

S791 995068 Parts of backtacking (with pedal) S791 642049 Cam for decorative stitching - standard S791 642037 Adjusting cam - plain stitch S980 094051 Connecting cable to drive EFKA DC 1600/DA82GA and EFKA VD 552/6F82FA

4.2.2 Sewing equipment

S791 124032 35 Sewing equipment 525 E 032 - standard S791 124033 35 Sewing equipment 525 E 033 S791 124034 35 Sewing equipment 525 E 034 S791 224075 35 Sewing equipment 525 E 075

4.2.3 Optional equipment

S791 149001 Equipment for overedging S791 235002 Unwinding device S791 224074 Throat plate 811768 (for stitching fine materials) S791 400023 Guiding for stitching together S791 630003 Equipment for stitching with two needles S791 642038 Cam for decorative stitching S791 642039 Cam for decorative stitching S791 642040 Cam for decorative stitching S791 642041 Cam for decorative stitching S791 642042 Cam for decorative stitching S791 642043 Cam for decorative stitching S791 642044 Cam for decorative stitching S791 642045 Cam for decorative stitching S791 642046 Cam for decorative stitching S791 642047 Cam for decorative stitching S791 642048 Cam for decorative stitching S791 642050 Cam for decorative stitching S791 642051 Cam for decorative stitching S791 642052 Cam for decorative stitching S791 642053 Cam for decorative stitching S791 642055 Cam for decorative stitching

S791 151016 Hinged foot with front thread slit - zig-zag stitch width 6 mm S791 151017 Hinged foot with front thread slit - zig-zag stitch width 10 mm S791 947001 Adjustment gauges S794 222012 Sewing lamp S791 995153 Presser foot lift via electromagnet S791 995154 Backtacking via electromagnet S980 094057 Push button for backtacking EFKA DC 1600/DA82GA S980 094060 Push button for backtacking EFKA VD 552/6F82FA S741 610518 40 High mortality spare parts kit in a plastics box

5. Technical data

Sewing speed 4400 SPM - maximum

3500 SPM - standard Stitch type double-thread lockstitch Stitch length max. 5 mm Pattern width continuously adjustable - max. 10 mm - according to the

respective accessory (cam) used Presser foot lifting 5 mm - via hand lever

7 mm - via knee lever, pedal, electromagnet Hook S980 008250 - horizontal, large diameter Needle system 134 No. 90-110 Drive clutch motor 2800 RPM (min. 0,35 kW)

stop motor (min. 0,4 kW) Head weight max. 38 kg Stand weight 61 kg Opening space of machine head 265 x 120 mm Bedplate dimension 178 x 476 mm Length of trimmed thread ends up to 20 mm Machine power imput with clutch motor max. 700 W Machine power imput with stop motor max. 800 W Equivalent sound pressure level of the machine alone at the working spot with 20 % utilization of the machine during the working shift at the standard sewing conditions 83 dB/A Ground plan machine dimensions (including stand) 1060 x 550 mm Machine height (including stand and thread stand) 1490 mm

Table 2

Equipment and their method of use

Trade Ordering No Number Number Pattern width One-needle type Two-needle type

marking of needle of needle

punches/ punches/

1 rev. pattern Max. Pattern Max. Pattern

of came machine machine

Stitch speed speed

length SPM SPM

525 E 002 S791 630002 Equipment for stitching with two needles for the subclass 101 - needle distance 3; 4; 5 mm 525 E 003 S791 630003 Equipment for stitching with two needles for the subclass 105 - needle distance 3; 4; 5 mm

525 E 037 S791 642037 12 - 4400 3800

1,5-5

525 Z 038 S791 642038 12 4 4,5 - 10

1-3

525 Z 039 S791 642039 12 12 4,5 - 10 3800 3400

1-3

525 Z 040 S791 642040 12 6 3,5 - 6 3800 3400

1,5-3

525 Z 041 S791 642041 12 12 4,5 - 10 3800 3800

1,5-5

525 Z 042 S791 642042 12 3 3,5 - 6 3800 3400

1,5-4

525 Z 043 S791 642043 12 4 4 - 6 3800 3400

1-3

525 Z 044 S791 642044 12 6 4 -10 3800 3400

1-3

525 Z 045 S791 642045 12 12 2 - 5 3800 3400

1,5-3

525 Z 046 S791 642046 12 12 2 - 5 3800 3400

1,5-3

3800

3400

(

525 Z 047 S791 642047 12 2 3,5 - 6 3800 3400

1-3

525 Z 048 S791 642048 12 12 4,5 - 10 3800 3400

1-3

525 Z 049 S791 642049 12 6 4,5 - 10 4400 3800

1-3

525 Z 050 S791 642050 12 4 2 - 6 3800 3400

1-3

525 Z 051 S791 642051 12 6 3,5 - 6 3800 3400

1,5-3

525 Z 052 S791 642052 12 2 2 - 4,5 3800 3400

1-3

525 Z 053 S791 642053 12 2 1 - 2,4 3800 3400

1-3

Table 2

Equipment and their method of use

Trade Ordering No Number Number Pattern width One-needle type Two-needle type

marking of needle of needle

punches/ punches/

1 rev. pattern Max. Pattern Max. Pattern

of came machine machine

Stitch speed speed

length SPM SPM

525 Z 055 S791 642055 12 3 3,5 - 6 3800 3400

1,5-4

6. Operation of the machine

Caution!

Do not use this sewing machine without using the finger guard (C, Fig. 4) and without the take-up lever guard (P, Fig. 2).

6.1 Upper thread threading (Fig. 1, 2)

Caution!

Before starting the threading operation, switch off the main switch and put off the feet from the pedals on the stand to avoid the starting of the machine by treading the pedal.

After having inserted the bobbin with thread on the thread stand (N), unwind the thread in sufficient length and pass it through the holes in the thread stand (N). Direct it then through the thread guide (A) and through the guide (B) - with the machines without any thread cutter, or through the auxiliary thread tensioner (L) with the machines provided with such thread cutter. Feed the thread between the dishes of the tensioner (C). Direct the thread through the adjusting spring (D) around the guide (E) and through the guide (F) and (G) into the take-up lever eye (H). From here the thread is directed downward through the guides (F) and (J) and through the hole of the thread guide (K) on the needle bar towards the needle eye. Thread the thread into the needle eye from the front (from the sewer) rearward.

MAIN SWITCH

OFF ON

Fig. 1

6.2 Winding of thread on the hook bobbin (Fig. 3)

From the thread stand the thread is directed to the tensioner (A) through the guide (B) on the machine head. From the guide the thread is directed on the hook bobbin mounted on the shaft (C) of the winder. Wind up the thread end several times on the bobbin in the clockwise direction and feed it towards the spring (D). Introduce the thread between the coils thereof and, when pulling it slightly, cut it with the knife which is mounted inside the spring. Engage the winder by means of the lever (E). After having wound up the thread on the bobbin, the winder stops automatically. After having removed the bobbin from the winder shaft it is possible to cut the thread with the knife protected by the spring (D) or to cut it with scissors. The thread (A) serves for regulating the tension of the thread for winding.

6.3 Needle insertion (Fig. 4)

Fig. 2

C D

Fig. 3

Caution!

Before starting the operation of the needle change, switch off the main switch and put the feet off the pedals on the stand to avoid the machine start by treading the pedal.

After having chosen the correct needle thickness (number) corresponding to the system of the prescribed type (usually the system 134), loosen the screw (A) in the needle holder and insert the needle (B) up to the bottom of the hole in the needle holder. Turn it in such a way, so that its long groove is directed ahead (towards the sewer). Caution - when choosing a thicker needle it is necessary to check, whether the hook beak does not catch the needle - the eventual setting of the hook position is to be carried out by a qualified person. Check up, whether the needle passes through the centre of the needle hole, change a faulty needle.

Fig. 4

6.4 Adjustment of the upper thread tension

(Fig. 1, 2, 5)

The tension of the upper and that of the bottom thread must be mutually adjusted in such a way, so that the stitch locking is being done in the middle of the sewn material (Fig. 5). The tension of the upper thread is to be adjusted by turning a bit the nut of the tensioner (M, Fig. 2). In turning the nut to the right (in the clockwise direction), we increase the tension of the upper thread, in turning it in the opposite direction, we reduce the tension of the thread. When the machine is provided with a thread cutter of thread (version

-105), its correct function is to be given major attention in adjusting correctly the thread tension. It is necessary to set correctly the auxiliary tensioner (L, Fig. 1) the function of which influences the length of the upper thread end which is projecting from the needle eye after having cut the thread. When correctly setting of the tensioner, the quality of the initial stitches is good and no unthreading of the thread out from the needle occurs. When increasing the adjusted tension of the auxiliary tensioner this end is shorter (the seam starts are of better quality), but there is an increased danger that this length will not be sufficient for starting further stitching, when the thread would leave the needle eye. In the opposite case, namely with a too small tension, the given ends are uselessly too long which worsens the quality of the stitch start on the rear side of the sewn material.

Correct adjustment of the tension of both threads

Incorrect adjustment

Fig. 5

6.5 Change of the hook bobbin, threading and setting of the bottom thread tension (Fig. 6, 7)

Caution!

Do not start the machine before placing the hook covers in their working (protective) position.

Before changing the bobbin in the hook, switch off the main switch and put your feet off the pedals on the stand to

avoid the machine start by treading the pedal.

Using the flap (F), remove the bobbin case from the hook. Put the full bobbin (A) into the bobbin case (B) and guide the thread through the groove (C) under the braking spring (D) and then into the hole (E). Let free about 5 – 6 cm of the thread end. It is recommended to turn the bobbin in the arrow direction when pulling the thread. After having inserted the bobbin case into the hook be sure in assuring this by the flap (F). As usual, by means of the the upper thread, we thread the bottom thread above the throat plate. The tension of the bootom thread is regulated by a screw (G). In turning it in the (+) direction, the pulling power increases, in the (-) direction it is reduced. When the tension of the bottom thread is correctly adjusted, then a good stitch laying is generally being ensured by the respective adjustment of the upper thread tension by means of the tensioner nut.

Fig. 6

Fig. 7

6.6 Adjustment of the stitch length, reverse stitching (Fig. 8, 9)

The stitch length is changed in turning the knob (A), which is placed on the arm web, according to the numbers indicating the stitch length against the symbol (B) on the machine arm. In turning the knob in the direction of the arrows, the stitch length is increased (+) or reduced (-). The direction change of feeding the stitched material is mechanically controlled by the reversible stitch lever (C) in pushing it in the direction of the arrow (S). According to the chosen accessory, the machine can be provided with an electromagnetic backtacking control (see Part B, par.

8) or with a control by a backward stitch pedal (P).

B A C

Fig. 8a

Fig. 8b

6.7 Adjustment of the pattern width (Fig. 9)

Caution! Danger of injury!

Switch off the main switch! Before starting the setting operation, wait until the motor stops!

Before any pattern width change. it is necessary to stop the machine with the needle in its top position. According to the table 2, mount the cam for the desired pattern and the pattern width is to be set in such a way, so that it suits the interval of the respective cam indicated in the table 2. The pattern width is continuously adjustable. Setting is to be done after having removed the guard on the machine arm on the lever (E) which controls the movement of the needlebar holder. Using a key, loosen the nut (G) on the screw (H), on which the draw bar from the needlebar holder is mounted. When shifting the screw in the slot of the lever (E) downwards, the pattern is being narrowed, in shifting it upwards, the stitched pattern is widened. When setting the maximum width of the patern, check the needle to avoid its striking into the throat plate. Lock the set up position with the nut (G). When using the accessory for sewing with two needles, the pattern width is to be set in such a way, so that the needles pass with sufficient clearance within the needle groove of the throat plate.

6.8 Regulation of the presser foot pressure, presser foot lifting (Fig. 10)

Fig.9

The pressure of the presser foot is regulated using an adjusting screw in the hole (A) which is placed below the top cover of the machine arm and is accessible from above through the hole in this cover. In turning the adjusting screw in the direction of the arrows we increase (+) or reduce (-) the pressure of the presser foot. The pressure of the presser foot must be sufficient for ensuring a reliable and continuous feeding of the sewn materila with the maximum sewing speed. A correct adjustment of the pressure of the pressure bar influences, whether the sewn material is being continuously fed without any damage and whether the stitch length is uniform. The mechanical lifting of the presser foot is enabled by means of the hand lever (B) which when lifted arrests the presser foot in its top position. The presser foot can be lifted with the knee lever or with the left pedal too according to the machine subclass. The assembling procedure of the automatic presser foot lifting using electromagnet is described in the part B, par. 7.

Fig. 10

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Duerkopp Adler 525 Operating Instruction

Specifications and Main Features

Frequently Asked Questions

User Manual