Dürkopp Adler 52 i Series Operating instructions

52Xi
52Xi-75
Service Instructions

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Property of Dürkopp Adler GmbH and protected by copyright. Any reuse of these contents,
including extracts, is prohibited without the prior written approval of Dürkopp Adler GmbH.
Copyright © Dürkopp Adler GmbH 2021
IMPORTANT
READ CAREFULLY BEFORE USE
KEEP FOR FUTURE REFERENCE

Table of Contents
Service Instructions 52Xi, 52Xi-75 - 00.0 - 11/2021 1
1 About these instructions .........................................................3
1.1 For whom are these instructions intended?................................3
1.2 Representation conventions – symbols and characters.............3
1.3 Other documents........................................................................5
1.4 Liability........................................................................................5
2 Safety.........................................................................................7
2.1 Basic safety instructions.............................................................7
2.2 Signal words and symbols used in warnings..............................8
3 Working basis ......................................................................... 11
3.1 Order of the adjustments..........................................................11
3.2 Laying the cable guide..............................................................11
3.3 Removing the covers................................................................12
3.3.1 Access to the underside of the machine...................................12
3.3.2 Removing and placing the arm cover.......................................13
3.3.3 Removing and placing the head cover .....................................14
3.3.4 Disassembling and assembling the throat plate.......................15
3.3.5 Disassembling and assembling the slide plate.........................15
3.3.6 Disassembling and assembling the feed dog...........................16
3.4 Flats on shafts ..........................................................................16
3.5 Locking the machine in place ...................................................17
4 Zigzag stitch mechanism of machines 523, 524, 527..........19
4.1 Tooth clearance setting of zigzag stitch gear ...........................19
4.2 Straight stitch alignment ...........................................................20
4.3 Zigzag stitch width....................................................................21
4.4 Needle stab position setting in feeding direction ......................22
4.5 Lateral setting of needle stab position......................................23
4.6 Lateral setting of central straight stitch position........................24
4.7 Lateral setting of straight stitches on throat plate needle
hole edges, arresting of zigzag stitch setting mechanism ........25
5 Form stitch mechanism of machine 525 ..............................27
5.1 Tooth clearance setting of form stitch gear...............................27
5.2 Roller bolt position of form stitch steering cam.........................29
5.3 Setting of needle stab position..................................................30
5.4 Timing of form stitch steering cam to needle motion ................30
6 Feeding and presser foot.......................................................31
6.1 Stitch length setting mechanism...............................................31
6.2 Zero stitch length......................................................................32
6.3 Feed dog position in throat plate recess and its height ............33
6.4 Timing of feed dog motion eccentric.........................................34
6.5 Backtacking with solenoid.........................................................36
6.6 Manual foot lifting......................................................................37
6.7 Foot lifting with knee lever........................................................38
6.8 Foot lifting with solenoid ...........................................................39
7 Needle bar and hook ..............................................................40
7.1 Needle bar height, needle and hook point clearance ...............40
7.2 Bobbin case driver....................................................................41

Table of Contents
2Service Instructions 52Xi, 52Xi-75 - 00.0 - 11/2021
7.3 Hook lifting................................................................................42
8 Thread mechanism.................................................................44
8.1 Thread limiter and check spring................................................44
8.2 Bobbin winder...........................................................................46
9 Thread trimming .....................................................................47
9.1 Trimming pressure between knives..........................................47
9.2 Trimming lever..........................................................................48
9.3 Driver........................................................................................49
9.4 Trimming cam...........................................................................50
10 Puller........................................................................................51
10.1 Synchronous operation of bottom feed and puller....................52
10.2 Distance from puller to needle..................................................53
10.3 Puller lifting...............................................................................54
10.4 Toothed belt tensioning ............................................................56
10.5 Puller pressure..........................................................................57
10.6 Feeding wheel replacement......................................................58
10.7 Setting of cam torsion spring pressure on step length setting
wheel screw..............................................................................60
10.8 Disk brake pressure setting......................................................61
11 Electronic control and sewing machine drive ..................... 62
12 Maintenance............................................................................65
12.1 Cleaning....................................................................................66
12.2 Lubricating................................................................................68
12.2.1 Lubricating the machine head...................................................69
12.2.2 Hook lubrication........................................................................70
12.3 Parts list....................................................................................71
13 Decommissioning...................................................................73
14 Disposal...................................................................................75
15 Errors in the sewing process ................................................77
16 Technical parameters.............................................................79

About these instructions
Service Instructions 52Xi, 52Xi-75 - 00.0 - 11/2021 3
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 Ser-
vice.
Consider these instructions as part of the product and keep it easily acces-
sible.
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. 7).
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.
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

About these instructions
4Service Instructions 52Xi, 52Xi-75 - 00.0 - 11/2021
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. 7).
Location
information If no other clear location information is 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 52Xi, 52Xi-75 - 00.0 - 11/2021 5
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
6Service Instructions 52Xi, 52Xi-75 - 00.0 - 11/2021

Safety
Service Instructions 52Xi, 52Xi-75 - 00.0 - 11/2021 7
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 location at 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 Use a lifting carriage or stacker to transport the machine. Raise the
machine 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 regulationsconcerningindustrialsafety and the protectionof
the environment.
Allthe warningsandsafety signs onthemachine mustalwaysbe 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:
• Setting up the machine
• 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
8Service Instructions 52Xi, 52Xi-75 - 00.0 - 11/2021
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
essential 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 52Xi, 52Xi-75 - 00.0 - 11/2021 9
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 seri-
ous 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
10 Service Instructions 52Xi, 52Xi-75 - 00.0 - 11/2021
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 52Xi, 52Xi-75 - 00.0 - 11/2021 11
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 cable guide
Ensure that all cables are laid in the machine such that the function of
moving parts is not hampered.
To lay the cable guide:
1. Lay any excess cable 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 cable can impair the functioning of moving machine parts.
This impairs the sewing function and can result in damage.
Lay excess cable as described above.

Working basis
12 Service Instructions 52Xi, 52Xi-75 - 00.0 - 11/2021
3.3 Removing the covers
For many types of work settings, you will have to remove the machine
covers first in order to access the components.
This chapter describes how to remove and then refit the individual covers.
The text for each type of work setting then specifies only the cover that
needs to be removed at that particular time.
3.3.1 Access to the underside of the machine
Cover
In order to access the components on the underside of the machine, you
must first swivel up the machine head.
Pic. 1: Access to the underside of the machine
WARNING
Risk of injury from moving parts!
Crushing possible.
Move the machine into the service position or
switch the machine off before removing the covers.
WARNING
Risk of injury from sharp parts!
Punctures possible.
Switch the machine off before removing the covers.

Working basis
Service Instructions 52Xi, 52Xi-75 - 00.0 - 11/2021 13
Tilting the machine head
1. Tilt the machine head as far as it will go.
Erecting the machine head
1. Erect the machine head.
3.3.2 Removing and placing the arm cover
Pic. 2: Removing and placing the arm cover
Removing the arm cover
1. Loosen the screws (2).
2. Remove the arm cover (1).
Placing the arm cover
1. Place the arm cover (1).
2. Tighten the screws (2).
(1) - Arm cover (2) - Screws
①②

Working basis
14 Service Instructions 52Xi, 52Xi-75 - 00.0 - 11/2021
3.3.3 Removing and placing the head cover
Pic. 3: Removing and placing the head cover
Removing the head cover
1. Loosen the screws (2).
2. Remove the head cover (1).
Placing the head cover
1. Place the head cover (1).
2. Tighten the screws (2).
(1) - Head cover (2) - Screws
①
②

Working basis
Service Instructions 52Xi, 52Xi-75 - 00.0 - 11/2021 15
3.3.4 Disassembling and assembling the throat plate
Pic. 4: Disassembling and assembling the throat plate
Disassembling the throat plate
1. Loosen the screws (2).
2. Remove the throat plate (1).
Assembling the throat plate
1. Insert the throat plate (1).
2. Tighten screws (2).
3.3.5 Disassembling and assembling the slide plate
Pic. 5: Disassembling and assembling the slide plate
Disassembling the slide plate
1. Loosen screws (2).
2. Remove the slide plate (1).
Montáž zásuvné desky
1. Insert the slide plate (1).
2. Tighten screws (2).
(1) - Throat plate (2) - Screws
②
①
(1) - Slide plate (2) - Screws
②
①

Working basis
16 Service Instructions 52Xi, 52Xi-75 - 00.0 - 11/2021
3.3.6 Disassembling and assembling the feed dog
Pic. 6: Disassembling and assembling the feed dog
Disassembling the feed dog
1. Loosen the screws (2).
2. Remove the feed dog (1).
Assembling the feed dog
1. Insert the feed dog (1).
2. Tighten the screws (2).
Important
Check the feed dog settings (p. 33).
3.4 Flats on shafts
Pic. 7: Flats on shafts
Some shafts have flat surfaces at the points where the components are
screwed on. This stabilizes the connection and makes setting easier.
The first screw in the direction of rotation is always screwed on to a flat
surface.
Important
Always ensure that the screws are completely flush with the surface.
(1) - Feed dog (2) - Screws
②
①
(1) - Flat (2) - Shaft
①
②

Working basis
Service Instructions 52Xi, 52Xi-75 - 00.0 - 11/2021 17
3.5 Locking the machine in place
Pic. 8: Locking the machine in place (1)
For some settings, the machine must be locked in place. To do this, the
locking pin (3) from accessory pack is inserted into a slot (2) on the arm
shaft crank (1), blocking arm shaft.
Pic. 9: Locking the machine in place (2)
Locking the machine in place
1. Remove the plug from the locking opening (4).
2. Turn the handwheel until the arresting groove (2) isin front of the lock-
ing opening (4).
3. Insert the locking pin (3) with end ø 5 mm into arresting groove (2).
Removing the lock
1. Pull the locking pin (3) out from arresting groove (2).
2. Insert the plug into the locking opening (4).
(1) - Arm shaft crank
(2) - Arresting groove
(3) - Locking pin
(4) - Locking opening
①② ③
④

Working basis
18 Service Instructions 52Xi, 52Xi-75 - 00.0 - 11/2021