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Global ZZ 1560 Series Instruction Manual & Instruction For Service Manual

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  • Page 2 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.
  • Page 3 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 in full knowledge of the instruction book and operated by persons with appropriate training. 2.

  • Page 4: Table Of Contents

    Table of contents Page Part 2 - Installation Instructions - 52Xi Scope of machine supply ........Complete machine transport packing .
  • Page 5 For your notes:...

  • Page 6: Scope Of Machine Supply

    Scope of machine supply The purchaser can order a complete machine or just some of the components. Check before installation whether all parts are available. These instructions describe assembly of a partly disassembled machine the components of which are completely supplied by the company Dürkopp Adler AG.

  • Page 7: Complete Machine Transport Packing

    Complete machine transport packing If the sewing machine is supplied as a complete machine, the following transport packing must be removed: – safety straps and wooden slats on machine head and stand – safety blocks and straps on sewing drive Stand assembly Stand frame assembly –...

  • Page 8: Mounting Of Table Top With Clutch Motor

    Stand table assembly 3.2.1 Mounting of table top with clutch motor – Turn the table top (1) upper side down. – Screw the drawer (2) on. – Set the oil tray (3) so that the oil tray inside aligns with the recess in the table top and screw it on.

  • Page 9: Mounting Of Table Top With Dc1550/Da321G Positioning Motor

    3.2.2 Mounting of table top with DC1550/DA321G positioning motor – Turn the table top (1) upper side down. – Screw the drawer (2) on. – Set the oil tray (3) so that the oil tray inside aligns with the recess in the table top and screw it on.
  • Page 10 3.2.3 Mounting of table top with integrated drive on machine head – Turn the table top (1) upper side down. – Screw the drawer (2) on. – Set the oil tray (3) so that the oil tray inside aligns with the recess in the table top and screw it on.

  • Page 11: Stand Height Setting

    Stand height setting – The stand height is adjustable between 750 and 900 mm. – Loosen the screws (1). – Set the required table top height and make sure that it is identical on both sides. To do so, make use of the scale on the stand feet. Set the stand height so that it corresponds with the operator´s bodily proportions.

  • Page 12: Machine Head Fixing Into Stand

    Machine head assembly Machine head fixing into stand 4.1.1 Motor under table top – Insert the machine head (1) in the recess in the table top according to the picture. 4.1.2 Motor integrated on machine head – Tilt the machine head (1) slightly and insert it in the recess in the table top.

  • Page 13: Adjustment Of Machine Blocking Switch

    4.1.3 Adjustment of machine blocking switch – The maschine adjust so that, the microswitch must be switched on in the machine working position. – Loosen the screws (1), the microswitch shifting in the groove (2) until the sound of the switch switching (a click) is heard. –...

  • Page 14: Mounting Of V-Belt Driven Machine Head

    Mounting of V-belt driven machine head – Mount the V-belt pulley (1) which is a part of the motor supply - if it was ordered from the supplier Dürkopp Adler. The belt pulley should have dimensions according to the table below. –...
  • Page 15 Belt pulley selection according to the motor and machine class FIR 1148/552/3 motor, power frequency 50 Hz, motor speed 2800 rpm Data unit 523i 524i 525i 527i operating sewing speed 3230 3230 3230 2150 belt pulley outer diameter belt pulley order number S980 000050 S980 000050 S980 000050...

  • Page 16: Mounting Of Belt Guards

    Mounting of belt guards – If the machine is equipped with the positioning motor, first mount pins (2) on the belt guard (1) /they are included in the accessories/. – Partly screw two screws (3) in the machine head. – Fix the belt guard (1), screw the screw (4) down and slightly tighten all fastening screws.

  • Page 17: Mounting Of Positioning Motor Control Panel

    Mounting of positioning motor control panel – The control panel (1) is supplied on request with machines with the positioning motor. The same applies to the panel holder (2). The illustrated control panel has Efka V810 marking. Also a more comfortable panel V820 can be mounted on the same holder (picture in the spare parts catalog).

  • Page 18: Mounting Of Connecting Cable

    Mounting of connecting cable – If the machine is equipped with the positioning motor, the machine head is electrically connected to the motor control box by means of a connecting cable (1). The connecting cable is included in the accessories. –...
  • Page 19 4.6 Lighting installation – Screw the roll (2) with the screw (1) to the machine head, fix the lighting lamp on the roll (2) and tighten with a handle (3). – The transformer installation is described in section 3.2.

  • Page 20: Machine Electric Connection

    Machine electric connection The machine motor is fed from the low voltage network. Attention! All works on the machine electric installation may be performed by an authorized electrician only. It is absolutely necessary to study the instructions supplied by the manufacturer about the motor! Machine connection to low voltage network According to the selected type, the machine motor has a single-phase...
  • Page 21 5.1.1 Lighting transformer connection to network voltage Attention! Danger of electric injury! The lighting transformer is not switched-off by the main switch (EN 60 204-31)! At the lighting installation and repair works in the transformer box, e .g. a fuse replacement, the network plug must be disconnected from the network unconditionally.

  • Page 22: Grounding

    Grounding – The grounding conduit (1) is included in the machine accessories. – Connect the conduit (1) to the plug (2) and pull its opposite end under the table top. – Screw the opposite end of the grounding conduit to the respective grounding point of the motor (marked –...
  • Page 23 Machine head connection to EFKA DC1550/DA321G motor – Connect the machine head connecting cables to the connector (1). – Connect the control panel to the connector (2). – Connect the position sensor connector in the motor to the connector (B2). –...

  • Page 24: Setting Of Efka Positioning Motor

    Setting of Efka positioning motor The function of the positioning motor is determined by its program, setting of the motor parameters and the machine stop positions. If the sewing machine is supplied as disassembled, the motor setting must be performed by the purchaser. If the sewing machine is supplied as complete, the motor is already set by the sewing machine manufacturer.

  • Page 25: Parameter Values

    6.1.3 Parameter values The description of parameter entering is in the publication attached by the motor manufacturer “Efka Operation Instructions” or on the website www.efka.net. Parameter Original value New value Parameter description 290* Machine class 1000 Max. sewing speed Reference position (see 6.2.1) Switch on angle of thread trimmer Delay angle of tensioner release * Parameter necessary to be entered as the first.

  • Page 26: Checking Of Set Positions

    6.2.3 Checking of set up positions Position 1 – Switch the network switch on – Tread the pedal forwards shortly and release. The machine stops in position 1 (see 6.2.1). Position 2 – Tread the pedal forwards shortly first and then with heel fully backwards until the machine stops.
  • Page 27 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.
  • Page 28 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 in full knowledge of the instruction book and operated by persons with appropriate training. 2.
  • Page 29 Table of contents Page Introduction and safety instructions Part 1 - Instructions for use - 52Xi Machine description ......... . . Machine use .
  • Page 30 For your notes:...

  • Page 31: Machine Description

    Machine description · A flatbed single-needle machine. · It sews a double-thread zig-zag lockstitch. · It has a bi-directional drop feed. · The machine is equipped with a horizontal hook. · Wick lubrication. · There is an automatic bobbin winder on the machine arm. ·...

  • Page 32: Subclasses

    Subclasses Class and subclass Needle Hook Foot Thread Backtacking number lifting trimming (closing) 523i 411001 523i 447001 524i 811001 524i 847001 525i 811001 525i 847001 527i 811001 527i 847001...

  • Page 33: Sewing Equipment

    Sewing equipment „ ‚ Stehová deska Podavač Patka Throat plate Feed dog Foot ƒ … E-Nr. Für Unterklasse / For Subclass E-No. Abb.-Nr. Verwendungszweck / Use Fig.No. 523 E 069 523i 411001; 523i 447001 Sewing equipment, 3-lined feed dog, needle size Nm 80-110, stitch length max.
  • Page 34 „ ‚ Stehová deska Podavač Patka Šicí vybavení Throat plate Feed dog Foot ƒ … E-Nr. Für Unterklasse / For Subclass E-No. Abb.-Nr. Verwendungszweck / Use Fig.No. 527 E 060 527i 811001; 527i 847001 Sewing equipment for two needle cordin seams with or without filler cord, 3-lined feed dog, needle size Nm 110-130, stitch length max.

  • Page 35: Optional Equipment

    Optional equipment Order number Optional equipment S359 600030 Complete motor FIR 1148/552/3 S359 600057 Complete motorEFKA DC1550/DA321G 9800 330009 Control panel V810 (for EFKA motor) 9800 330010 Control panel V820 (for EFKA motor) S080 836491 Control panel V810 or V820 bracket S072 500100 Complete stand (including stand table top) S615 000316...
  • Page 36 Cams for shape sewing for subclass 525i Commercial Order number Quantity Quantity sewing Pattern width Single-needle Double-needle Marking sewing points/ points/pattern 1 cam turn Stitch length Z 037 S080 674219 4400 3800 Z 038 S080 674113 4,5 - 10 3800 3400 Z 039 S080 674114...

  • Page 37: Technical Parameters

    Technical parameters Class and subclass 523i 411001 524i 811001 525i 811001 527i 811001 523i 447001 524i 847001 525i 847001 527i 847001 Zig-zag stitch max. width/mm Maximum sewing speed according to for stitch length 6 mm 5000 4400 cams used 3400 Maximum sewing speed according to for stitch length 8 mm...

  • Page 38: Machine Operation Needle Threading

    Machine operation Needle threading Attention! Danger of injury! Thread when the main switch is switched off and motor stopped! – Do the threading according to picture (A) and detail (B). – When trimming the material edges, do the threading according to picture (A) and detail(C).

  • Page 39: Hook Thread Winding

    Hook thread winding – Fix the bobbin (1) on the winder. – Do the threading according to picture (A), wind 5 times round the bobbin. – Insert the thread under cutter (2) and tear off by pulling in the arrow direction (3).

  • Page 40: Bobbin Fixing And Hook Threading

    Bobbin fixing and hook threading Attention! Danger of injury! Switch the main switch off and wait for the motor stopping. – Tilt the flap (1), grip it and pull the bobbin case (2) out of the hook. – Put the bobbin (3) in the bobbin case with the thread end (4) oriented according to the picture (2).

  • Page 41: Thread Tension Adjustment

    Thread tension adjustment 7.4.1 Needle thread tension adjustment Secondary tensioner adjustment (1) – Adjust the secondary tensioner (1) so that it has as small tension as possible, but high enough so as the thread cannot be pulled out from the tensioner (1) at the material removing after previous trimming (when the tensioner (2) is opened - switched off).

  • Page 42: Hook Thread Tension Adjustment

    7.4.2 Hook thread tension adjustment Attention! Danger of injury! Do adjustments when the main switch is switched off and motor stopped! – The hook thread tension depends on the adjustment of springs (1) and (2). Tension spring (1) adjustment – Remove the bobbin case (3) from the machine and insert a full-wound bobbin (4).

  • Page 43: Needle Replacement

    Needle replacement Attention! Danger of injury! Do the needle replacement when the main switch is switched off and motor stopped. – Loosen the screw (1) and remove the needle (2). – Fix a new needle and turn it so that the needle scarf (3) is oriented according to detail (D).

  • Page 44: Foot Lifting

    Foot lifting Foot lifting with a hand lever – Lift the foot by pressing the lever (1) to a stop (foot remains lifted). – Lower the foot by returning the lever (1) to initial position or by pressing the knee lever (2) /if there is any/ and by its subsequent releasing or by the automatic foot lifting by means of the pedal and subsequent pedal releasing.

  • Page 45: Foot Pressure Setting

    Foot pressure setting – Regulate the foot pressure by means of a screwdriver (1) which is supplied with the machine accessories. – The pressure increases by turning in the arrow direction and vice versa. – The foot pressure should be as small as possible, but strong enough so that the feeding is reliable even at a high sewing speed.

  • Page 46: Backtacking (Reverse Feeding; Closing Up)

    Backtacking (reverse feed; closing up) Backtacking with a hand lever(applies to manually controlled subclasses) – Press the lever (1) downwards. The machine will feed in the reverse direction until you release the lever. Backtacking with a microswitch (applies to automatically controlled subclasses) –...
  • Page 47 7.10 Setting of zig-zag stitch width (throw) and position Attention! At setting the zig-zag stitch width (throw) and position the needle must not be inside the sewn material. There is a threat of the needle breaking! Setting of zig-zag stitch width –...

  • Page 48: 7.11 Starting Up Of Manually Controlled Machine With Clutch Motor

    7.11 Starting up of manually controlled machine with clutch motor – Start up the motor (1) with the switch (2) - the drive motor is running continuously. – Tread the pedal (3). The drive friction clutch switches in this way and the sewing machine starts running.

  • Page 49: Control Of Machine Equipped With Clutch Positioning Motor

    7.12 Control of machine equipped with positioning motor and solenoid automatic control 7.12.1 Control pedal The pedal position is scanned with a proximity switch which distinguishes 16 levels. The meaning is in the table: Pedal position Pedal motion Meaning Heel fully backwards Command for thread trimming (seam finish) Heel slightly backwards Command for foot lifting...

  • Page 50: Key Control Panel

    7.12.2 Key control panel Function Hand backtacking When the key is pressed at sewing, the sewn material is fed backwards. Needle positioning in upper or bottom position By the parameter F-242 (DA321) the key function can be defined: 1 = needle up/down 2 = needle up 3 = one stitch (factory setting is 1)

  • Page 51: Efka Dc1550/Da321G Positioning Motor

    Efka DC1550/DA321G positioning motor DA321G control contains all needed control elements for a function switchover and parameter setting.The operation is possible without the control panel, the sewing programming is not enabled. To the machine control also control panels V810 and V820 can be connected which are available as an attachment.

  • Page 52: Sewing With Machine Equipped With Positioning Motor Machine Automatic Functions

    Sewing with machine equipped with positioning motor Machine automatic functions The machine has functions stated below which are automatically carried out during the seam sewing dependent on: – pre-selection – pedal position (according to the machine operator s selection) – work phase of seam sewing Automatic function Pre-selection...
  • Page 53 The automatic function pre-selections are described in the drive manufacturer s accompanying Instruction for Use. For Efka DA321G motor also see the drive manufacturer s Instruction for Use on website www.efka.net. Certain automatic functions can be pre-selected by means of keys. Their description is included in the publication Efka Instructions for Use, sections 4, 12, 13.

  • Page 54: Maintenance

    10. Maintenace 10.1 Cleaning and checking Attention! Danger of injury! Maintenance may be carried out only when the machine is switched off and the motor stopped! Attention! Maintenance must be carried out in prescribed intervals. Neglection of maintenance may result in malfunction requiring costly repair. Mainenance operation Maintenance interval Throat plate (1) disassembly.

  • Page 55: 10.2 Lubrication

    10.2 Lubrication Attention! Danger of injury! Oil may cause dermatic diseases. Avoid complexion staining with oil. In case of staining wash the affected spot in water with soap. Attention! Handling of mineral oils is subject of legal prescriptions. Deposit the debased oil in an authorized dangerous waste scrap-yard! Protect the environment.
  • Page 56 Oil lubrication – If the oil volume in the tank (1) drops to the level indicated with MIN mark,add oil through the hole (2) up to MAX mark. – Add oil into tank (3) through the hole (4) at least once a week until the oil starts flowing from the terminal(5).

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