Duerkopp Adler 528 Operating Instruction

Instruction manual

528

Minerva Boskovice, a.s., Sokolská 60, CZ - 680 17 Boskovice
Tel.: [phone], 453433, 494111 Fax: [phone] 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 ..................................................................................................................................................................... 2

6. Operation of the machine .................................................................................................................................................... 3

6.1 Upper thread threading ............................................................................................................................................ 3

6.2 Winding of thread on the hook bobbin ................................................................................................................... 3

6.3 Needle insertion ....................................................................................................................................................... 3

6.4 Adjustment of the upper thread tension ................................................................................................................. 4

6.5 Change of the hook bobbin, threading and setting of the bottom thread tension .............................................. 4

6.6 Adjustment of the stitch length, reverse stitching ................................................................................................. 5

6.7 Adjustment of the zigzag stitch width ..................................................................................................................... 5

6.8 Regulation of the presser foot pressure, presser foot lifting ................................................................................ 5

7. Machine maintenance ......................................................................................................................................................... 6

7.1 Cleaning .................................................................................................................................................................... 6

7.2 Lubrication ............................................................................................................................................................... 6

8. Electronic control of the machine ...................................................................................................................................... 7

8.1 Control of sewing by means of control elements ................................................................................................... 7

8.1.1 Via treadle ....................................................................................................................................................... 7

8.1.2 Via pushbutton ............................................................................................................................................... 7

8.1.3 Via control panel Efka V 810/V 820 ................................................................................................................ 7

8.2 Adjustment of automatic functions via control panel for stop motor ................................................................... 8

8.2.1 By using stop motor Efka with panel V 810 ................................................................................................... 8

8.2.1.1 Adjustment by means of buttons with fixed setting function ........................................................... 8

8.2.1.2 Setting by means of parameters ......................................................................................................... 9

8.2.2 By using stop motor Efka with panel V 820 ................................................................................................... 10

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

8.2.2.2 Setting by means of parameters ......................................................................................................... 11

Operating instructions for eventual trouble shooting ....................................................................................................... 13

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 mainly for sewing operations in the shoe manufacture for assembling quarters and linings, for sewing

through tongues, for sewing babouches and for decorative sewing of shoes. It is suitable for assembling leather and textile

materials in the fancy goods industry. In general, only dry material may be sewn on these machines, which should not be thicker

than 8 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

528-101 83 20

528-105 83 20

2. Description of the machine

It is flat-bed single-needle machine. It sews with double-thread zigzag lock-stitch, with two-way drop feed. The stitch length is

adjustable using a knob. The backward stitching is controlled by a hand lever, eventually, by pedal or by electromagnet in

accordance with the equipment of the machine. The width of the zig-zag stitch is adjustable with a lever on the machine arm. 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

528-101

528-105

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)

4.1.2 Sewing equipment

S791 124027 35 Sewing equipment 528 E 027 - standard

S791 124028 35 Sewing equipment 528 E 028 - sewing speed max. 1800 SPM

1

4.1.3 Optional equipment

S791 400023 Guide for sewing together

S791 149001 Attachment for serging operation

S791 151017 Hinged foot with front thread slit - zig-zag stitch width 10 mm

S791 947001 Adjustment gauges

S794 222012 Sewing lamp

S741 410106 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)

S980 094051 Connecting cable to drive EFKA DC 1600/DA82GA and EFKA VD 552/6F82FA

4.2.2 Sewing equipment

S791 124027 35 Sewing equipment 528 E 027 - standard

4.2.3 Optional equipment

S791 400023 Guide for sewing together

S791 149001 Equipment for overedging

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 410505 40 High mortality spare parts kit in a plastics box

5. Technical data

Sewing speed 2200 SPM - maximum

2000 SPM - standard

Stitch type double-thread zigzag lockstitch - 304

Stitch length max. 5 mm

Zig-zag stitch width max. 10 mm

Presser foot lifting 8 mm - via hand lever

10 mm - via knee lever, pedal, electromagnet

Hook S980 008253 - horizontal, large diameter

Needle system 134-35 No. 110-160 (-101)

system 134-35 No. 110-130 (-105)

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

2

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

H

F

J

P

A

B

G

D

C

M

H

A

L

N

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)

E

K

Fig. 2

B

A

C

D

E

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 134-35), 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.

3

A

B

C

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

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.

+

C

F

D

C

D

G

B

A

E

-

Fig. 6

F

Fig. 7

4

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).

6.7 Adjustment of the zigzag stitch width(Fig. 8)

Before any changing of the zig-zag stitch width, it is necessary to
stop the machine in such a way, so that the needle is in its top
position. Further it is necessary to turn a bit the arresting lever (D)
to the left (in counterclockwise direction) and to have it loosened
until having proceeded the required change of adjustment. In
turning a little the lever in the opposite sense (to the right), there
occurs blocking of the set up width of the zig-zag stitch.
The width of the zigzag stitch is continuously adjustable acording
to the machine types from 0 up to 10 mm. It is adjusted by the lever
(E) projecting above the cover (F) of the zigzag stitch mechanism.
In moving the lever to the right (towards the hand wheel) we increase
the width of the zigzag stitch up to the maximum, in moving the
lever to the left, we reduce the width of the zigzag stitch up to zero.

E

D

F

S

B

A

C

Fig. 8

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

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.

P

Fig. 9

+-

A

B

Fig. 10

5

7. Machine maintenance

Caution!

Before cleaning and lubricating the machine switch off the main switch and put your your feet off the pedals on the
stand to avoid starting the machine by treading the pedal.

7.1 Cleaning

Maintain the machine clean and at least once a day (according to the processed material) remove dirt from the hook and feeder
space by means of a brush, with the machines provided with a thread cutter, from the cutting space as well. Avoid using volatile
liquids for cleaning purposes, they damage the machine and the health too. Check up the filtering sieve on the electric motor for
not being choked with dust.

7.2 Lubrication (Fig. 11, 12, 13)

For lubricating the machine use Esso SP-NK 10 oil or another oil of the same quality (viscosity at 40° C: 10 mm2/s; inflammation
point: 150°C). Before starting the stitching operation, put one oil drop into the holes marked with red colour on the machine
(Fig. 12, 13). Check up specially the oil level on the oil level gauge (1) for lubricating the hook. Refill oil through the hole (2) above
the oil level gauge only when the oil lever considerably sinks below the middle of the oil level gauge.
From time to time, oil is to be dropped into the hole of the hook gearbox (Fig. 13). The quantity of the oil fed for lubricating the
hook is regulated by turning a bit a regulation pin (3) using a screwdriver within the extent of 0 - MAX, that is to the left, in
counterclockwise direction. The pin is placed on the front side of the oil vessel under the bedplate. When setting the indicator
of the regulation pin on “0”, the minimum oil feeding to the hook is ensured, so that its seizure is avoided. After having put the
machine into operation, check and refill regularly the oil level in the oil vessel at the hook and in the oil vessel on the machine arm.
It is necessary to refill ESSO BEACON EP2 grease in the shafts of the feeding mechanism (4, 5).

4

5

Fig. 11

12

3

Fig. 13Fig. 12

6

-1 -2

0

1 ÷ 13

Fig. 14

8. Electronic control of the machine

(it is valid for sub-classes equipped with stop motor)

8.1 Control of sewing by means of control elements

8.1.1 Via treadle (treadle positions and function
possibilities) (Fig. 14)

The position of the treadle is read by the reader, which can
recognise 16 levels. Its meaning is shown on the table and
see Fig. 14.

Treadle Treadle Meaning

position

Foot full backwards Command for thread

-2

-1

0 Neutral position Note

1

2

3

: : :

13

Foot slightly Commandlifting

Slightly forwards Command releasing

Continually Sewing at minimum

forwards speed (1. gear)

Continually Sewing at second

forwards speed level

Fully forwards Sewing at maximum

trimming (seam finishing)

the foot up

foot

speed (12. gear)

1

Fig. 15

Note: It is possible to pre-adjust the needle position (up/down)
and foot position (up/down) by stopping in seam (introduc­ing the treadle in neutral position). Foot position (up/down)
after seam finishing (pressing the treadle by foot fully back­wards).

8.1.2 Via pushbutton (Fig. 15)

The pushbutton has got a firmly set function of bar operation
(when depressing the push button during the sewing opera­tion, the sewn material is being reverse fed).

8.1.3 Via control panel Efka V 810/V 820
(Fig. 16, 17)

These functions are standardly assigned to the pushbuttons
A, B:

A - cancelling (recalling) the bar
B - needle up/down

Note: Function of the A,B pushbuttons can be changed by
different adjustment of parameters 293,294 (see original
operating instruction Efka DA82GA).

7