Duerkopp Adler 275 User manual

275
Spezialnähmaschine
mit Direktantrieb
Betriebsanleitung
Instruction manual
Postfach 17 03 51, D-33703 Bielefeld • Potsdamer Straße 190, D-33719 Bielefeld
Telefon [phone] - 00 • Telefax +49 (0) 521/ 9 25 24 35 • www.duerkopp-adler.com
GB
D
Ausgabe / Edition: Änderungsindex Teile-Nr./Part.-No.:
02/2002 Rev. index: 00.0 PrintedinGermany 0791 275740

Alle Rechte vorbehalten.
Eigentum der Dürkopp Adler AG und urheberrechtlich geschützt. Jede, auch
auszugsweise Wiederverwendung dieser Inhalte ist ohne vorheriges schriftliches
Einverständnis der Dürkopp Adler AG verboten.
All rights reserved.
Property of Dürkopp Adler AG and copyrighted. Reproduction or publication of the
content in any manner, even in extracts, without prior written permission of
Dürkopp Adler AG, is prohibited.
Copyright © Dürkopp Adler AG - 2002

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 in-
juries or damages to the machine.
1. The machine must only be commissioned in full knowledge 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 threading, 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, disconnect the machine from
the compressed air supply system (max. 7-10 bar).
Before disconnecting, reduce the pressure of the maintenance unit.
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.

Contents page:
Foreword and general safety instructions
Part 1: Operating instructions Class 275 Direct Drive
1. Product description .............................. 5
2. Designated use................................. 5
3. Subclasses ................................... 6
4. Accessories ................................... 7
5. Technical data ................................. 9
6. Operation
6.1 Threading the needle thread ......................... 11
6.2 Setting the needle thread tension ...................... 11
6.3 Releasing the needle-thread tension..................... 11
6.4 Winding on the bobbin thread ......................... 12
6.5 Fitting the hook thread bobbin ........................ 13
6.6 Setting the hook thread tension........................ 14
6.7 Changing needles................................ 15
6.8 Setting the thread regulator .......................... 16
6.9 Settingthesewing-footpressure....................... 17
6.10 Setting the overfeed-foot contact pressure ................. 17
6.11 Setting the stitch length ............................ 18
6.12 Raisingthesewingfoot ............................ 19
6.13 Lockingthesewingfootintheupposition.................. 19
6.14 Settingthevalueoftheoverfeed(fullness)................. 20
6.15 Limit on overfeed length ............................ 20
6.16 Edge cutter (Cl. 275-740642) ......................... 21
6.16.1 Automatically switching on the edge cutter with the first stitch ..... 21
6.16.2 Switching on the edge cutter with an automatic delay........... 22
6.16.3 Switching on the edge cutter manually ................... 22
6.16.4 Switching off the edge cutter automatically, by stitch count ....... 22
6.17 Edge cutter (Cl. 275-742642) ......................... 23
6.17.1 Automatically switching on the edge cutter with the first stitch ..... 23
6.17.2 Switching on the edge cutter with an automatic delay........... 24
6.17.3 Switching on the edge cutter manually ................... 24
6.17.4 Switching off the edge cutter automatically, by stitch count ....... 24
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6.18 Fullness control (Cl. 275-142342, 275-742642) .............. 25
6.18.1 General ..................................... 25
6.18.2 Operating terminal - description of the operating components ..... 25
6.18.3 Switchingthemachineon........................... 26
6.18.4 Sewing...................................... 26
6.18.4.1Smoothsewing................................. 26
6.18.4.2Sewingwithfullness.............................. 27
6.18.4.3Switchingbetweensmoothsewingandfullness.............. 27
6.18.4.4 Sewing with 8 programmed fullness sequences .............. 27
6.18.4.5 Alternately sewing right- and left-hand pieces with a
programmedfullness.............................. 28
6.18.5 Sequence advance by severing the thread ................. 28
6.18.6 Switching the edge cutter on and off (only Cl. 275-742642) ....... 28
6.18.7Displayingthecurrentprogram-switchingprograms........... 28
6.19 Keypadonthemachinearm.......................... 29
7. Sewing ...................................... 30
8. Maintenance
8.1 Cleaning and testing .............................. 32
8.2 Lubrication .................................... 33

1. Product description
The DÜRKOPP ADLER 275 is a special sewing machine with universal applications.
Basic type
Single-needle double-lockstitch machine with underfeed, differentiable-foot overfeed
and thread cutter for light to medium-heavy material with 4-mm stitch length and max.
8-mm overfeed length.
2. Designated use
The 275 is a special sewing machine designed to sew light material. Such material is
generally made of textile fibers, but it may also be leather. It is used in the clothing and
domestic-upholstery industries.
This sewing machine can also be used to produce so-called technical seams. In this
case, however, the operator must assess the possible dangers which may arise (with
which DÜRKOPP ADLER AG would be happy to assist), since such applications are on
the one hand relatively unusual and, on the other, they are so varied that no single set
of criteria can cover them all. The outcome of this assessment may require appropriate
safety measures to be taken.
Generally only dry material may be sewn with this machine. The material may be no
thicker than 6 mm when compressed by the lowered sewing feet. The material may not
contain any hard objects, since if it does the machine may not be operated without an
eye-protection device. No such device is currently available.
The seam is generally produced with textile-fibre sewing thread of gauge up to 30/2 Nm
(synthetic yarn) or 30/3 Nm (covering yarn). Before using any other thread the possible
dangers arising must be assessed and appropriate safety measures taken if necessary.
This special sewing machine may be set up and operated only in dry, well-maintained
premises. If the sewing machine is used in other premises which are not dry and
well-maintained it may be necessary to take further precautions (which should be
agreed in advance - see EN 60204-31: 1999).
As manufacturers of industrial sewing machines we proceed on the assumption that
personnel who work on our products will have received training at least sufficient to
acquaint them with all normal operations and with any hazards which these may involve.
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3. Subclasses
Cl. 275-140332 Like the basic type, but with automatic electromagnetic
bar-tacking and automatic foot elevation, a smaller feeder
lifting cam and an adapted regulator to improve the
smooth-sewing results with small stitch lengths and light
materials, a drive motor with control device attached to the
machine. Fitted as standard with keys for bar-tacking within the
seam, for needle up/down and for activating and suppressing
bar tacks.
Cl. 275-140342 Like the basic type, but with automatic electropneumatic
bar-tacking and automatic foot elevation, a drive motor with
control device attached to the machine. Fitted as standard with
keys for bar-tacking within the seam, for needle up/down and
for activating and suppressing bar tacks.
Cl. 275-142342 Like the basic type, but with automatic electromagnetic
bar-tacking and automatic foot elevation, a drive motor with
control device attached to the machine. Also fitted with a
fullness control with 8 preselectable fullness values operating
via a step motor, plus smooth sewing, that can be selected with
keys or the knee-switch. Fitted as standard with keys for
bar-tacking within the seam, for needle up/down, for activating
and suppressing bar tacks and fullness on/off.
Cl. 275-740642 Like the basic type. but with automatic electromagnetic
bar-tacking and automatic foot elevation, an
electropneumatically connectable edge cutter driven by an
electric motor, a drive motor with control device attached to the
machine. Fitted as standard with keys for bar-tacking within the
seam, for activating and suppressing bar tacks and switching
the edge cutter on and off.
Cl. 275-742642 Like the basic type, but with automatic electromagnetic
bar-tacking and automatic foot elevation, an
electropneumatically connectable edge cutter driven by an
electric motor. Drive motor with control device attached to the
machine. Also fitted with a fullness control with 8 preselectable
fullness values operating via a step motor, plus smooth sewing,
that can be selected with keys or the knee-switch. Fitted as
standard with keys for bar-tacking within the seam, for
activating and suppressing bar tacks. Edge cutter on/off and
fullness activated or not activated.
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4. Accessories
Subcl.
Material no. Equipment
0275 590034 Thread retractor X X X X X
0275 590014 Mechanical device to amplify
the overfeed during sewing (second pedal) XX X
0275 590044 Electropneumatic device to amplify the
overfeed via keys during sewing XX X
N900 020038 Swivel-down right edge stop
adjustment range 0-40 mm XXX
N900 040037 Swivel-down right edge stop with 2 mm, 5
mm or 10 mm stages XXX
N900 003601 Intermediate plate for particularly intensive
fullness XXXX
N005 225303 Edger, divided edger, pneumatic swivel-up
mechanism, for light material with 6-mm
seam width, containing N005 005302 edger
and N005 005301 attachment with Z100
001041 pneumatic switch unit
XXX
0271 002121 K conversion kit, 170% hook X X X X X
0271 590014 “Oil-free” hook conversion kit X X X X X
0271 000661 Knee lever add-on kit X X X X
0271 590024 Infrared reflex light barrier X X X X X
0271 590034 Photoelectric residual-thread monitor for
the looper thread XXXXX
9800 330009 Efka V810 operating panel X X X X X
9800 330010 Efka V820 operating panel X X X X X
9830 515031 Operating-panel attachment bracket X X X X X
9822 510001 Sewing lamp (Waldmann halogen) X X X X X
0APP 001041 Sewing-lamp installation kit X X X X X
0798 500088 Sewing-light transformer X X X X X
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275-140332 275-140342 275-142342 275-740642 275-742642

Subcl.
9822 510000 Tripod sewing lamp X X X X X
9822 510011 Table clamp for tripod sewing lamp
9822 510000 XXXXX
9780 000108 WE8 maintenance unit X X X X X
0797 003031 Pneumatic- system connection pack X X X X X
MG53 400015 MG53-3, 1060x500 X X X X X
MG53 400016 MG53-3, 1060x600 X X X X X
MG53 400017 MG53-3, 1250x900/700 X X X X X
MG53 400018 MG53-3, 1060x600/table-plate opening
rotated by 10°X
8
275-140332 275-142042 275-140342 275-740642 275-742642

5. Technical data
Subclasses
Class 275
Type of stitch 301
Hook type horizontal hook
Number of needles 1
Needle system 134, 797 or Sy 195 501
Max. needle thickness
(depending on E no.) [Nm] 70 - 120
Max. sewing-thread thickness 30
Max. stitch length
- forwards [mm] 4
- backwards [mm] 4
Max. overfeed length [mm] 8
Max. speed [min-1] 5000
Factory set speed [min-1] 4800
Sewing-foot stroke
- when lifted [mm] 7
Operating pressure [bar] n/a n/a 6 n/a 6
Air consumption [NL] n/a n/a 0.02 n/a 0.02
Length, width, height [mm] 500 x 175 x 380
Weight [kg] 36 36 37 38 39
Design-voltage range [V/Hz] 1 x 190 - 240 V 50/60 Hz
Factory set design voltage [V/Hz] 1 x 230 V 50/60 Hz
Design power [kVA] 0,5
Noise: workplace-related emission value conforms to DIN 45635-48-A-1-KL2
Lc [dB (A)] 84
Stitch length [mm] 3.2
Speed [min-1] 4800
Material
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275-140332 275-140342 275-142342 275-740642 275-742642

Fig. a: Correct thread interlacing in
the centre of the material
Fig. b: Needle-thread tension too low
or
hook thread tension too high
Fig. c: Needle-thread tension too high
or
hook thread tension too low
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6. Operation
6.1 Threading the needle thread
Caution: danger of injury
Turn off the main switch.
The needle thread may only be threaded with the machine
turned off.
–Place the yarn reel on the reel stand as shown in the illustration.
–Thread the needle thread as shown in the diagram on the preceding page.
6.2 Setting the needle thread tension
Setting the needle thread pre-tensioner
The needle thread main tensioner 4 is opened while the thread is cut, but to ensure that
the thread is cut reliably the needle thread must be under slight residual tension. This
residual tension is produced by the needle thread pre-tensioner 1.
The pre-tensioner 1 simultaneously affects the length of the end of the cut needle
thread, and hence the thread length needed for the next secure seam start.
Basic setting: Turn knurled nut 2 until its front is flush
with the bolt 3.
To shorten the starting thread: Turn knurled nut 2 clockwise
To lengthen the starting thread: Turn knurled nut 2 anti-clockwise.
Important: After major changes to the needle-thread pre-tensioner it may
be necessary to adjust the main tensioner 4 in order to achieve
consistent results.
Adjusting the main tensioner
The needle-thread pre-tensioner 1 and main tensioner 4 together produce the thread
tension required for the seam (see fig. a).
Adjustment:
To increase tension: turn the knurled nut 4 clockwise
To reduce tension: turn the knurled nut 4 anti-clockwise
6.3 Releasing the needle-thread tension
Automatic
The main tensioner 4 is automatically raised when the thread is cut.
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6.4 Winding on the bobbin thread
Caution: danger of injury
Turn off the main switch.
Threading of the bobbin thread should only be done with
the sewing machine switched off.
–Place the bobbin on the bobbin-winder shaft 1.
–Thread the bobbin thread as shown in the illustration.
–Wind the bobbin thread clockwise onto the bobbin core.
–Pull the thread end through the cutter clamp 2 and cut.
–Swivel the bobbin-winder flap 3 against the bobbin.
–Turn on the main switch.
–Commence sewing.
–The bobbin winder automatically switches off when the pre-set quantity of thread
has been wound on (see Servicing instructions).
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6.5 Fitting the hook thread bobbin
Caution: danger of injury
Turn off the main switch.
The hook thread bobbin may only be fitted with the machine
turned off.
Removing the bobbin
–Raise the bobbin-housing flap 1.
–Remove the bobbin-housing top 2 with the bobbin.
–Remove the empty bobbin from the bobbin-housing top 2.
Fitting the full bobbin
–Place the full bobbin 3 in the bobbin-housing top 2.
–Pull the hook thread through slit 4 under tension spring 6 and into hole 5.
–Pull about 5 cm of hook thread out of bobbin-housing top 2.
When the thread is pulled out the bobbin must rotate in the direction of the arrow.
–Replace the bobbin-housing top 2 in the shuttle.
–Close bobbin-housing flap 1.
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5
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6.6 Setting the hook thread tension
Caution: danger of injury
Turn off the main switch.
The hook thread tension may only be adjusted with the
machine turned off.
Setting the hook thread tension
The hook thread tension setting must be such as to produce a seam like the one shown
in fig. a) in section 6.
–At a recommended hook thread tension of 30g, for example, 15g should be
produced by the braking spring 1 and 15g by the tension spring 4.
–The basic setting for the tension spring 4 is as follows:
The bobbin housing must slowly descend under its own weight. See the sketch in section 6.5.
The braking spring 1 prevents the bobbin from running on when the thread is cut.
The two tension values are adjusted as follows:
–Unscrew the regulating screw 3 until the leaf spring 4 is no longer under tension.
–Set the braking spring 1 by screwing in the regulating screw 2 until half the
recommended shuttle-tension value is exerted by the braking spring.
–Place the bobbin in the bobbin-housing top and thread the looper thread (see section 6.5).
–Place the bobbin housing with bobbin in the shuttle.
–Turn the handwheel until the machine has completed one stitch.
–Use the needle thread to pull the looper thread to the top of the stitch hole.
–Pull the looper thread downwards at an angle of 45°in the direction of sewing.
About half the tension value should be perceptible.
Then tighten regulating screw 3 to the recommended tension value.
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6.7 Changing needles
Caution: danger of injury
Turn off the main switch.
The needle may only be changed with the machine turned
off.
–Undo screw 1 and remove needle.
–Insert the new needle as far as it will go into the hole in needle bar 4.
CAUTION:
The throat 2 must point in the direction of the shuttle tip 3
(see sketch).
–Tighten screw 1.
CAUTION:
After changing to a needle of a different thickness the
distance between the shuttle and the needle must be
adjusted (see Service instructions).
Failure to carry out this adjustment may lead to the following errors:
–Changing to a thinner needle: - faulty stitches
- damage to thread
–Changing to a thicker needle: - damage to the shuttle tip and needle
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GB
4
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6.8 Setting the thread regulator
The thread regulator 2 regulates the amount of needle thread necessary for stitch
formation. Only a properly-adjusted thread regulator ensures an ideal sewing result.
The setting depends on the following factors:
–stitch length
–material thickness
–yarn characteristics
At the correct setting the upper-thread loop 6 must slide at low tension over the shuttle.
Caution: danger of injury
Turn off the main switch.
The thread regulator may only be adjusted with the
machine turned off.
–Loosen screw 5.
–Adjust thread regulator 2.
The vertical wire 3 acts as an adjustment aid in combination with scale 4
(standard value: 2.5).
–Tighten screw 5.
Note on adjustment:
When the thread regulator 2 is correctly adjusted, the following must apply:
–When thread loop 6 passes the thickest part of the shuttle, the thread-tensioning
spring 1 must be pulled about 1 mm downwards from its upper end position. 1 mm
is a standard value. It may be higher or lower, depending on the tension of the
thread-tensioning spring 1.
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6.9 Setting the sewing-foot pressure
The required sewing-foot pressure is set with adjustment wheel 2.
–Undo locknut 3.
–To increase the sewing-foot pressure = turn adjustment wheel 2
clockwise.
To reduce the sewing-foot pressure = turn adjustment wheel 2
anti-clockwise.
–Tighten locknut 3.
CAUTION:
The sewing-foot pressure of the overfeed foot must only be
checked with the overfeed foot in contact with the feeder.
6.10 Setting the overfeed-foot contact pressure
The required pressure for the overfeed foot (grip-feed) is set with adjustment wheel 1.
–To increase the overfeed-foot pressure = Turn adjustment wheel 1
clockwise.
To reduce the overfeed-foot pressure = Turn adjustment wheel 1
anti-clockwise.
CAUTION:
The sewing-foot pressure and overfeed-foot contact
pressure must only be checked with the overfeed foot in
contact with the feeder.
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6.11 Setting the stitch length
Adjustment wheels
The stitch length is set with adjustment wheel 1 for sewing forwards, with adjustment
wheel 2 for sewing backwards.
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