867 Operating Instructions
All rights reserved. Property of Dürkopp Adler AG and protected by copyright. Any reuse of these contents, including extracts, is prohibited without the written approval in advance of Dürkopp Adler AG.
Table of contents 1 1.1 1.2 1.3 1.4 1.5 1.6 About this manual ................................................................................. 5 Scope of application of the manual.......................................................... 5 Applicable documentation........................................................................ 5 Damage during transport ......................................................................... 5 Limitation of liability................................................
Table of contents 2 5.10.1 5.11 5.11.1 5.11.2 5.11.3 5.11.4 5.12 5.12.1 5.12.2 5.12.3 5.12.4 5.13 5.13.1 5.13.2 5.14 5.15 5.16 5.17 Removing blocking of the adjusting wheel ............................................ 48 Setting the sewing foot stroke ............................................................... 49 Limiting of number of stitches with an increased sewing foot stroke..... 49 Setting the stroke height........................................................................
Table of contents 7.12 7.12.1 7.12.2 7.12.3 7.12.4 7.12.5 7.12.6 7.12.7 7.12.8 7.12.9 7.13 7.13.1 7.13.2 7.13.3 7.14 7.15 Electrical connection.............................................................................. 90 Checking the mains voltage................................................................... 90 Fitting and connecting the sewing lamp and sewing lamp transformer . 90 Establishing equipotential bonding ........................................................
Table of contents 4 Operating instructions 867 - 02.
About this manual 1 About this manual 1.1 Scope of application of the manual This operating manual describes the set-up and intended use of the special sewing machine 867. It applies to all subclasses listed in Chapter 3.4 Technical data. 1.2 Applicable documentation The device contains built-in components of other manufacturers, e.g. drive motors.
About this manual 1.5 Symbols used Correct setting Specifies the correct setting. Faults Specifies the faults that can occur due to an incorrect setting. Steps to be performed when operating the machine (sewing and equipping) Steps to be performed for servicing, maintenance and installation Steps to be performed via the software control panel The individual steps are numbered: 1. 1. First step 2. 2. Second step ... The sequence of the steps must always be followed.
Safety instructions 2 Safety instructions This chapter contains basic instructions for your safety. Read the instructions carefully before setting up, programming, maintaining or operating the machine. Make sure to follow the information included in the safety instructions. Failure to do this can result in serious injury and damage to the machine. 2.1 General safety instructions Only authorized persons may use the machine. Every person who works with the machine must have read the operating manual first.
Safety instructions Inspect the machine while in use for any externally visible damage. Interrupt your work if you notice any changes to the machine. Report any changes to your supervisor. A damaged machine may not be used any more. Machines or machine parts that have reached the end of their service life must not continue to be used. They must be disposed of according to the applicable legal requirements. The machine may only be set up by qualified specialists.
Safety instructions 2.2 Signal words and symbols used in safety instructions The safety instruction text is surrounded by colored bars. Signal words specify the severity of a danger: • • • • Danger: Death or serious injury will occur. Warning: Death or serious injury is possible. Caution: Moderate to minor injuries are possible. Attention:Material damage is possible.
Safety instructions Examples of the layout of the safety instructions in the text: DANGER Type and source of the danger Consequences in the event of noncompliance Measures for avoiding the danger This is what a hazard note looks like for a hazard that will result in serious injury or even death if not WARNING Type and source of the danger Consequences in the event of noncompliance Measures for avoiding the danger This is what a hazard note looks like for a hazard that could result in serious injury or even
Performance description 3 Performance description 3.1 Features The Dürkopp Adler 867 is a flatbed sewing machine for double lockstitches.
Performance description 3.2 Declaration of conformity The machine complies with the European regulations specified in the declaration of conformity or in the installation declaration. 3.3 Intended use The Dürkopp Adler 867 is intended for sewing moderately heavy to heavy material.
Performance description 3.4.
Performance description Sewing stitch type -394342 -393342 1 Needle system 134-35 Maximum needle strength [Nm] 180 80/3 – 10/3 15/3 20/3 Stitch length, forwards / backwards [mm] 80/3 – 15/3 10/3 80/3 – 10/3 12 / 12 Adjustable stitch lengths 1 Maximum number of stitches 2 1 3400 Number of stitches on delivery 3000 3400 Maximum fan height (*only with reversing mechanism) 20 20* 3000 20 9 Positive operating pressure [bar] 6 Air consumption [NL] 2 3000 Maximum sewing foot stroke
Performance description Sewing stitch type Vertical hook, large (L) x x x x x x x Number of needles x x 2 Needle system 134-35 130 180 Maximum sewing thread size 80/3 – 10/3 Stitch length, forwards / backwards [mm] -490322 -290445 -290342 -290322 -290142 Double lockstitch 301 Vertical hook, extra-large (XXL) Maximum needle strength [Nm] -290122 -290040 -290020 Subclasses: 867- -260122 Short arm 2-needle machines 7/7 15/3 12 / 12 Adjustable stitch lengths 1 Maximum number
Performance description Sewing stitch type Double lockstitch 301 Vertical hook, large (L) Vertical hook, extra-large (XXL) x x Number of needles 134-35 Maximum needle strength [Nm] 180 Maximum sewing thread size 80/3 – 10/3 Stitch length, forwards / backwards [mm] Maximum number of stitches Number of stitches on delivery Maximum fan height (*only with reversing mechanism) x 1 Needle system Adjustable stitch lengths 12 / 12 1 3400 2 3800 20* 9 Positive operating pressure [bar] 6 Length/w
Performance description Sewing stitch type Vertical hook, large (L) x x -190342-70 x x Number of needles x 1 Needle system 134-35 Maximum needle strength [Nm] 180 Maximum sewing thread size 80/3 – 10/3 Stitch length, forwards / backwards [mm] 12 / 12 1 1 1 Maximum number of stitches 3000 Number of stitches on delivery 3000 Maximum fan height (*only with reversing mechanism) -190322-70 Double lockstitch 301 Vertical hook, extra-large (XXL) Adjustable stitch lengths -190122-70 -19
Performance description -290322-70 x x 2 2 Double lockstitch 301 x Vertical hook, extra-large (XXL) x x x Number of needles 2 Needle system 134-35 Maximum needle strength [Nm] 180 Maximum sewing thread size 80/3 – 10/3 Stitch length, forwards / backwards [mm] Adjustable stitch lengths -290342-100 Vertical hook, large (L) -290342-70 Sewing stitch type -290122-70 -290040-70 Subclasses: 867- -290020-70 Long arm 2-needle machines 12 / 12 1 1 1 2 Maximum number of stitches 3000
Performance description 3.4.3 Additional equipment and manuals Additional equipment and manuals can be requested from the Dürkopp Adler Applications Center (APC). E-mail: marketing@duerkopp-adler.com Additional manuals and further Documentation are available in the download area of the Dürkopp Adler Internet site: http://www.duerkopp-adler.com/de/main/Support/downloads. Operating instructions 867 - 02.
Performance description 20 Operating instructions 867 - 02.
Device description 4 Device description Figure 1: General overview - Long arm machine example < 1 2 ^ 3 4 0 5 6 9 8 7 (1) - Adjusting wheels for the sewing foot stroke (2) - Adjusting wheel for the sewing foot pressure (3) - Thread tensioners (4) - Keypad on the machine arm (5) - Sewing foot with needle (6) - Hook (under the needle plate) (7) - Bobbin winder for the hook thread (8) - Adjusting wheels for the stitch length (9) - Oil level indicator (10) - Handwheel (11) - Stitch adjustment lever (12)
Device description 22 Operating manual 867 - 02.
Operating instructions 5 Operating instructions 5.1 Switching the power supply on and off The lower main switch (2) on the control regulates the power supply. Figure 2: Switching the power supply on and off 4 1 – + 3 2 (1) - Indicator lamp on the keypad (2) - Indicator lamp on the control (3) - Main power switch (4) - Switch for the sewing lamp To switch on the power: 1. Press the main switch (3) down to position I. The indicator lamps (1) and (2) light up. To switch off the power: 1.
Operating instructions 5.2 Inserting and replacing the needle WARNING Risk of injury by the needle point and moving parts. Switch off the sewing machine before replacing the needle. Do not touch the needle point. Sequence After changing to a needle of a different size adjust the clearance between the hook and the needle ( Service instructions Chapter 11.1 Adjusting the hook side clearance).
Operating instructions 5.2.1 Needle change on 1-needle machines Figure 3: Inserting and changing needles on 1-needle machines 1 2 3 4 (1) - Needle bar (2) - Fastening screw (3) - Groove (4) - Hook 1. Turn the handwheel until the needle bar (1) reaches the upper end position. 2. 3. 4. 5. Loosen the fastening screw (2). Pull the needle out towards the bottom. Insert the new needle. Important: Align the needle so that the groove (3) faces the hook (4). 6. Tighten the fastening screw (2).
Operating instructions 5.2.2 Needle change on 2-needle machines Figure 4: Inserting and changing needles on 2-needle machines 1 2 3 4 (1) - Needle bar (2) - Fastening screw (3) - Groove (4) - Hook 1. Turn the handwheel until the needle bar (1) reaches the upper end position. 2. 3. 4. 5. Loosen the fastening screws (2) on both sides. Pull each of the needles out downwards. Insert new needles on both sides. Important: Align the needles so that the grooves (3) face away from each other.
Operating instructions 5.2.3 Changing needles on switchable needle bars Figure 5: Inserting and changing needles on switchable needle bars 1 2 3 4 (1) - Needle bar (2) - Fastening screw (3) - Groove (4) - Hook 1. Turn the handwheel until the needle bars (1) reach the upper end position. 2. 3. 4. 5. Loosen the fastening screws (2) on both sides. Pull each of the needles out downwards. Insert new needles on both sides. Important: Align the needles so that the grooves (3) face away from each other.
Operating instructions 5.3 Threading in the needle thread WARNING Risk of injury by the needle point and moving parts. Switch off the sewing machine before inserting the thread. In all machines the thread from the thread reel is fed to the machine via the unwinding bracket. Figure 6: Thread guide on the unwinding bracket and machine arm 1 2 (1) - Guide on unwinding bracket (2) - Thread reel holder 1. Fit the thread reel on the thread reel holder (2). 2.
Operating instructions 5.3.1 Needle thread threading on 1-needle machines Figure 7: Threading procedure for needle thread - part 1 9 4 5 6 8 7 – + 1 – + + – + 1234 + 2 – 3 + (1) - Tightening lever (2) - Spring tip (3) - Thread tensioning spring (4) - Diverter pin 6 5 4 (5) - Main tensioner (6) - Additional tensioner (7) - Preliminary tensioner (8) - 2nd Thread guide (9) - 1st Thread guide 1. Insert the thread from the rear to the front through the left hole in the 1st thread guide (9).
Operating instructions Figure 8: Threading procedure for needle thread - part 2 - 1234 0 + ^ . < + , (10) - Hook (11) - Upper thread guide (12) - lower thread guide (13) - Thread guide on the needle bar (14) - Needle eye (15) - Thread regulator (16) - Thread lever 9. Guide the thread under the hook (10). 10. Insert the thread from bottom to top through the hole on the thread regulator (15). 11. Insert the thread from the right to the left through the thread lever (16). 12.
Operating instructions Short thread 13. For machines with a short thread cutter: cutter Insert the thread through the left hole of the thread guide above the thread clamp. 14. Insert the thread through the left hole of the thread guide below the thread clamp. Figure 9: Thread clamp (short thread cutter) 15. Slide thread from the left in the thread clamp, so that the thread is held in the hooks of the clamp. The thread should run almost without contact through the thread clamp.
Operating instructions 5.3.2 Needle thread threading on 2-needle machines 2-needle machines are equipped with a second tensioning screw triangle for the 2nd needle thread. The threading procedure corresponds to that for the 1st needle thread ( Section 5.3.1 Needle thread threading on 1-needle machines, Page 29).
Operating instructions 5.3.3 Needle thread threading on machines with a clean seam start The clean seam start parts set provides a short and cleanly sewn needle thread at the start of the seam. After the 1st stitch the needle thread is clamped by the thread clamp (6) and pulled back by the thread retractor (5) so that the needle thread only protrudes by a small amount. The exact settings are described in Additional manual 0791 867708.
Operating instructions 5.4 Inserting and winding on the hook thread WARNING Risk of injury by the needle point and moving parts. Switch off the sewing machine before inserting the thread. Figure 12: Thread guide on the unwinding bracket and machine arm 1 2 (1) - Guide on unwinding bracket (2) - Thread reel holder 1. Fit the thread reel on the thread reel holder (2). 2. Insert the thread from the rear to the front through a hole in the guide on the unwinding bracket (1).
Operating instructions Figure 13: Winding on the hook thread – part 1 1 4 5 6 9 1 2 – 2 4 + – – + – + 1234 3 + (1) - Thread guide (2) - Preliminary tensioner (3) - Bobbin (4) - Hook thread guide 3. Insert the thread in a wavelike manner through the 3 holes of the thread guide (1): from top to bottom through the left hole, from bottom to top through the hole in the middle and finally from top to bottom through the right hole. 4.
Operating instructions The hook thread is normally wound on when sewing is in progress. However, you can also wind on the hook thread without sewing, e.g. if you require a full bobbin in order to start sewing. ATTENTION Damage to the sewing feet or needle plate possible if the thread is wound on without material. Lock the sewing feet in place in the highest position and adjust the sewing foot stroke to the smallest value if you wind on hook thread without sewing material. Winding procedure 1.
Operating instructions 5.5 Replacing the hook thread bobbin WARNING Risk of injury by the needle point and moving parts. Switch off the sewing machine before replacing the hook thread bobbin. Figure 15: Replacing the hook thread bobbin 6 5 1 4 3 2 (1) - Slot (2) - Guide (3) - Tension spring (4) - Slot (5) - Bobbin (6) - Bobbin housing flap 1. Fold up the bobbin housing flap (6). 2. Remove the empty bobbin. 3.
Operating instructions Automatic For machines with automatic residual thread monitor: residual thread If the hook thread needs to be replaced, the LED indicator monitor lamps (2) light up on the machine arm. The left light is for the lefthand hook and the right light is for the right-hand hook. Figure 16: Residual thread monitor – 1 + 2 (1) - Vision slot on the bobbin (2) - LEDs on the machine arm The bobbin plate has vision slots on one side.
Operating instructions 5.6.1 Adjusting the needle thread tension The 3 tension-adjusting wheels on the tensioning screw triangle determine the needle thread tension. In the basic position, the top of the adjusting wheel is flush with the screw in the center. 1 – + Figure 18: Adjusting the needle thread tension – + – + 1234 2 3 (1) - Preliminary tensioner (2) - Additional tensioner (3) - Main tensioner To increase the tension: 1. Turn the adjusting wheel clockwise. To reduce the tension: 1.
Operating instructions 1 – + Figure 19: Preliminary tension – + – + 1234 2 3 (1) - Preliminary tensioner (2) - Additional tensioner (3) - Main tensioner Preliminary tension The preliminary tensioner (1) holds the thread in position if the main tensioner (3) and additional tensioner (2) are completely open. Automatic For machines with automatic thread cutter: thread cutter The preliminary tension (1) also determines the length of the initial thread for the new seam: Short initial thread: 1.
Operating instructions Additional tensioner The additional tensioner (2) increases the tension during sewing, e.g. for thickened seams. Correct setting The additional tension (2) must always be selected lower than the main tension (3). The additional tension can be switched on and off manually or automatically.
Operating instructions 5.6.2 Removing blocking of the needle thread tension Automotive: Machines with blockable adjusters are used especially in the Blockable automotive sector. With these machines the blocking must be adjusters removed before the sewing foot pressure can be adjusted. + – + – – – + – + + – + 1234 1 – + Figure 21: Removing blocking of the needle thread tension 2 (1) - Fastening screw (2) - Retaining plate 1. Loosen the fastening screws (1). 2.
Operating instructions 5.6.4 Adjusting the hook thread tension WARNING Risk of injury by the needle point and moving parts. Switch off the sewing machine before adjusting the hook thread tension. Figure 22: Adjusting the hook thread tension 1 (1) - Adjusting screw The hook thread tension is adjusted using the adjusting screw (1). To increase the tension: 1. Turn the adjusting screw (1) clockwise. To reduce the tension: 1. Turn the adjusting screw (1) counterclockwise. Operating instructions 867 - 02.
Operating instructions 5.7 Setting the thread regulator WARNING Risk of injury by the needle point and moving parts. Switch off the sewing machine before setting the thread regulator. The thread regulator determines the tension applied to guide the needle thread around the hook. Correct setting: The loop of the needle thread slides at low tension over the thickest point of the hook. Figure 23: Setting the thread regulator 1 – + 1234 2 + (1) - Regulator screw (2) - Thread regulator 1.
Operating instructions 5.8 Venting the sewing foot • • ECO machines: Mechanically via the knee lever CLASSIC machines: Electro-pneumatically via a foot pedal 5.8.1 Mechanical lifting with the knee lever Figure 24: Mechanical sewing foot lifting with the knee lever 1 (1) - Knee lever 1. Push the knee lever (1) to the right. The sewing feet remain open while the knee lever is pushed to the right. 5.8.
Operating instructions 5.9 Locking the sewing feet in the upper position There is a lever at the back of the machine for holding the sewing feet in the upper position. Figure 26: Holding the sewing feet in the upper position with the lever 1 (1) - Sewing feet in upper position (2) - Upper position canceled 2 To hold the sewing feet in the upper position: 1. Push the lever down. To cancel the lock: 1. Push the lever up. You can also use the foot pedal to cancel the upper position: 1.
Operating instructions 5.10 Setting the sewing foot pressure The adjusting wheel at the top left determines the contact pressure of the sewing foot on the material to be sewn. The pressure can be adjusted continuously by turning the wheel. The correct pressure depends on the material to be sewn: • • Lower pressure for soft materials, e.g. cloth Higher pressure for harder materials, e.g. leather Correct setting The material being sewn does not slip and is correctly transported.
Operating instructions 5.10.1 Removing blocking of the adjusting wheel Automotive: Machines with blockable adjusters are used especially in the Blockable automotive sector. With these machines the blocking must be adjusters removed before the sewing foot pressure can be adjusted. Figure 28: Removing blocking of the sewing foot pressure adjustment wheel 1 3 2 (1) - Fastening screw (2) - Retaining plate (3) - Adjusting wheel for the sewing foot pressure 1. Loosen the fastening screw (1). 2.
Operating instructions 5.11 Setting the sewing foot stroke 5.11.1 Limiting of number of stitches with an increased sewing foot stroke CLASSIC machines have a potentiometer on the arm shaft. The potentiometer automatically adapts the number of stitches to the sewing foot stroke: If you increase the sewing foot stroke, the number of stitches is automatically reduced. Important: ECO machines do not have automatic reduction of the number of stitches.
Operating instructions 5.11.2 Setting the stroke height Depending on the equipment the machine has 1 or 2 adjusting wheels for the sewing foot stroke. The sewing foot stroke is continuously adjustable over a range of 1 – 9 mm by turning the adjusting wheel. On machines with 2 adjusting wheels, the left adjusting wheel (1) sets the normal sewing foot stroke and the right adjusting wheel (2) sets the elevated sewing foot stroke.
Operating instructions 5.11.3 Quick stroke adjustment via knee switch On machines with quick stroke adjustment activated via a knee switch the elevated sewing foot stroke is switched via the knee switch. The toggle switch on the rear side of the knee switch determines whether the elevated sewing foot stroke is permanently switched on or only while the knee switch is pressed. Figure 30: Quick stroke adjustment via knee switch 1 2 (1) - Knee switch (2) - Toggle switch For permanent conversion: 1.
Operating instructions The elevated sewing foot stroke is retained as long as the knee switch is pushed to the right. • To switch off the elevated sewing foot stroke: Release the knee lever (1). 5.11.4 Removing blocking of the sewing foot pressure adjustment wheel Automotive: Machines with blockable adjusters are used especially in the Blockable automotive sector. With these machines the blocking must be adjusters removed before the sewing foot stroke can be adjusted.
Operating instructions 5.12 Stitch length 5.12.1 Adjusting the stitch length Depending on the equipment the machine has 1 or 2 adjusting wheels for the stitch length. The stitch length can be adjusted continuously between 0 – 12 mm.
Operating instructions 5.12.
Operating instructions 5.12.3 Removing blocking of the adjusting wheel Automotive: Machines with blockable adjusters are used especially in the Blockable automotive sector. With these machines the blocking must be adjusters removed before the stitch length can be adjusted. WARNING Risk of injury from moving parts. Switch off the sewing machine before removing blocking of the stitch length adjusting wheels.
Operating instructions 5.12.4 Sewing backwards The stitch adjustment lever on the machine arm reduces the stitch length down to sewing backwards in the lower end position. Figure 35: Stitch adjustment lever on the machine arm 1 2 1 (1) - Stitch adjustment 1. Slowly push the stitch adjustment lever (1) down. The stitch length becomes smaller. In the lower end position, the machine sews backwards with the stitch length selected at the adjusting wheels. 56 Operating instructions 867 - 02.
Operating instructions 5.13 Quick functions on the keypad Depending on the subclass, the machine has a keypad on the machine arm allowing activation of particular functions while sewing. 5.13.
Operating instructions Figure 37: Function keys 2 3 4 5 6 7 +/– Key for sewing backwards (2): If the key (2) is selected the machine sews backwards. Key for the position of the needle (3): If the key (3) is selected the needle moves to a specific position. This position is determined individually via the parameter settings. For more information read the Service instructions. On delivery, the machine is set so that the needle is moved up when the key (3) is activated.
Operating instructions 5.13.2 Transferring a key function to the additional switch You can transfer one of the key functions to the additional switch. Select a function that you require frequently to be able to switch it on faster while sewing.
Operating instructions 5.14 Switching the binder On machines with a binder the + and – above the needle bar defined the path followed by the binder. Figure 39: Switching the binder 1 (1) - Plus key • • • 2 (2) - Minus key No key pressed: The binder follows the same path as the transporter. Plus key pressed: Bind an outer bow The binder follows a longer path. Minus key pressed: Bind an inner bow The binder follows a shorter path.
Operating instructions 5.15 Switching switchable needle bars On machines with switchable needle bars the needle bars can be individually switched on and off via the L and R keys. Figure 40: Switching switchable needle bars 1 2 (1) - L - Key for the left needle bar (2) - R - Key for the right needle bar Switching off a needle bar: 1. Press the key for the desired needle bar. The key lights up. The needle bar is switched off. Switching on a needle bar: 1. Press the illuminated key.
Operating instructions 5.16 Operating the controller Depending on the subclass, the machine is operated with an Efka or a DAC controller ( Section 7.7 Controller, Page 82). Operation of the controller is described in a controller-specific operating manual. • • 62 Efka DC1550/DA321G controller The manufacturer's operating manual is provided in the accessory pack delivered with the controller.
Operating instructions 5.17 Sewing WARNING Risk of injury from the needle tip on unintentional start of sewing. Take care not to accidentally press the foot pedal when your fingers are in the needle tip area. The foot pedal starts and controls the sewing process.
Operating instructions To interrupt sewing: 1. Release the foot pedal in pedal position 0: The machine stops, needles and sewing feet are down. To continue sewing: 1. Press the foot pedal forwards to the pedal position +1: The machine continues to sew. To sew over thickened seams: 1. Activate the elevated sewing foot stroke using the knee lever ( Chapter 7.12 Sewing foot stroke). To change the stitch length: 1. Switch on the 2nd stitch length using the key for the quick function ( Chapter 7.
Maintenance 6 Maintenance This chapter describes simple maintenance work that needs to be carried out on a regular basis. This maintenance work can be carried out by the operating personnel. Advanced maintenance work may only be carried out by qualified specialists. Advanced maintenance work is described in the Service instructions. 6.1 Cleaning work 6.1.1 Cleaning the machine Sewing dust and thread remains must be removed every 8 operating hours using a compressed-air pistol or a brush.
Maintenance Figure 42: Points that need to be cleaned particularly thoroughly 4 1 3 2 (1) - Area around the needle (2) - Hook (3) - Area under the needle plate (4) - Cutter on the bobbin winder Areas particularly susceptible to soiling: • • • • Cutter on the bobbin winder for the hook thread (4) Area under the needle plate (3) Hook (2) Area around the needle (1) Cleaning steps: 1. Switch off the power supply at the main switch. 2.
Maintenance 6.1.2 Cleaning the motor fan sieve The motor fan sieve must be cleaned with a compressed air piston once a month. In the case of very fluffy material to be sewn, the motor fan sieve must be cleaned more frequently. WARNING Risk of injury due to flying particles. Switch off the machine at the main power switch before cleaning the motor fan sieve. Flying dirt particles can get in the eyes, causing injury. Hold the compressed-air pistol in such a way that no particles fly near persons.
Maintenance 6.2 Checking the oil level WARNING Skin injuries due to contact with oil. Oil can cause a rash if it comes into contact with the skin. Avoid any skin contact with the oil. If oil gets on your skin, wash the affected skin areas thoroughly. Figure 44: Oil level indicator 1 MAX MIN 2 3 (1) - Refill opening (2) - Maximum level marking (3) - Minimum level marking Checking the oil level 1.
Maintenance Figure 45: Oil level indicator 1 MAX MIN 2 3 (1) - Refill opening (2) - Maximum level marking (3) - Minimum level marking Topping up with oil Pour in oil through the refill opening (1) as required: 1. Switch off the sewing machine at the main switch. 2. Pour in oil, up to but not past the maximum level marking (2). 3. Switch on the sewing machine at the main switch.
Maintenance Oil to be used: Only DA 10 or an oil of equivalent quality may be used for the machine, which has the following properties: • • Viscosity at 40° C: 10 mm²/s Flash point: 150 °C ATTENTION Machine damage possible due to incorrect oil. An incorrect oil type can cause damage to the machine. Only use oil that complies with the data in the operating manual. ENVIRONMENTAL Risk of environmental damage from oil. Oil is a pollutant and must not enter the sewage system or the soil.
Maintenance 6.3 Checking the pneumatic system Figure 46: Pressure indicator on the maintenance unit 6 4 8 1 2 10 0 2 (1) - Reference value: 6 bar (2) - Pressure indicator Check the pressure: 1. Check the pressure at the pressure indicator (2) each day. Reference value: 6 bar. Important: The pressure must not deviate from the reference pressure by more than 1 bar. ATTENTION Machine damage possible due to incorrect pressure. An incorrect pressure can cause damage to the machine.
Maintenance Water condensation accumulates in the water separator of the maintenance unit. Figure 47: Water level in the maintenance unit 6 4 8 2 10 0 1 2 3 (1) - Filter element (2) - Water separator (3) - Drain screw Check the water level: 1. Check the water level every day. Important: The condensation water must not rise up to the level of the filter element (1). Drain water as required: 1. Switch off the sewing machine at the main switch. 2. Place the collection tray under the drain screw (3). 3.
Maintenance 6.4 Repairs Contacts for repair in the event of damage to the machine: Dürkopp Adler AG Potsdamer Str. 190 33719 Bielefeld Ph. +49 (0) 180 5 383 756 Fax +49 (0) 521 925 2594 Email: service@duerkopp-adler.com Internet: www.duerkopp-adler.com Operating instructions 867 - 02.
Maintenance 74 Operating instructions 867 - 02.
Set-up instructions 7 Set-up instructions WARNING Risk of injury. The machine may only be set up by trained specialists. Wear safety gloves and safety shoes when unpacking and setting up. 7.1 Checking the scope of delivery Important: The scope of delivery depends on your specific order. 1. Prior to set-up, check that all parts are present.
Set-up instructions Standard equipment: • Machine head (10) • Oil pan (9) • Thread reel holder with unwinding bracket (11) • Controller (8) • Keypad for the controller (1) Optional additional equipment: • Table plate (2) • Drawer (3) • Frame (4) • Pedal (5) • Knee lever/switch (6) • Maintenance unit (7) • Sewing light (not illustrated) 7.2 Removing the transport securing devices All transport securing devices must be removed prior to set-up. 1.
Set-up instructions 7.3 Fitting the frame components Figure 49: Fitting the frame components 1 2 3 1 8 4 2 7 4 3 6 5 5 (1) - Head sections of the inner bars (2) - Inner bars (3) - Frame bars (4) - Cross bar(s)* (5) - Frame foot struts (6) - Cross strut (7) - Adjusting screw (8) - Oil can holder 1. Screw the cross bar(s)* (4) onto the frame bars (3). 2. Screw the oil can holder (8) at the rear to the upper cross bar (4). 3. Screw the cross strut (6) onto the foot struts (5). 4.
Set-up instructions 7.4 Completing the table plate The table plate belongs to the optional delivery scope. Drawings are provided in Appendix to allow you to independently assemble a table plate. 7.4.1 Completing a short arm table plate 60 mm (500 mm) Figure 50: Completing a short arm table plate 1 7 40 mm 2 6 5 3 4 (1) (2) (3) (4) - Machine head support Recess for hinge lower parts Drawer Oil pan (5) - Cable duct (6) - Corner projections (7) - Thread reel holder 1.
Set-up instructions 7.4.2 Completing a long arm table plate Figure 51: Completing a long arm table plate 1 2 7 6 5 3 (1) - Cable duct (2) - Cutout for hinge lower parts (3) - Drawer (4) - Oil pan 4 (5) - Corner protrusions (6) - Hole (7) - Thread reel holder 1. Screw the drawer (3) with the left-hand bracket to the underside of the table plate. 2. Screw the oil pan (4) in place under the recess for the machine. 3. Screw the cable duct (1) to the underside of the table plate. 4.
Set-up instructions 7.5 Fastening the table plate to the frame Figure 52: Fastening the table plate to the frame 1 1 (1) - Screw holes and screws 1. Place the table plate on the head sections of the inner bars. 2. Screw the table plate firmly in place at the screw holes (1). 80 Operating instructions 867 - 02.
Set-up instructions 7.6 Setting the working height The working height is continuously adjustable between 750 and 900 mm (clearance between the floor and upper edge of the table plate). Figure 53: Setting the working height 1 (1) - Screws WARNING Risk of crushing. The table plate can sink under its own weight when the screws on the frame bars are released. This applies even more when the machine head is already fitted. Ensure that your hands are not jammed when releasing the screws. 1.
Set-up instructions 7.
Set-up instructions 7.7.1 Fitting the control The DAC controllers and Efka controllers are installed according to the same principle. Figure 54: Fitting the control 1 3 2 (1) - Strain relief (2) - Control (3) - Screw holder 1. Screw the control (2) onto the 4 screw holders (3) under the table plate. 2. Clamp the power cable of the control (2) into the strain relief mechanism (1). 3. Screw the strain relief (1) under the table plate. Operating instructions 867 - 02.
Set-up instructions 7.7.2 Fit the pedal and setpoint device Figure 55: Fitting the setpoint device SWG DAC 6 5 SWG Efka 6 5 1 2 3 4 (1) - Pedal rod (2) - Screw (3) - Cross strut 10° (4) - Pedal (5) - Setpoint device (6) - Angle 1. Fit the pedal (4) on the cross strut (3) and align it in such a way that the middle of the pedal is under the needle. The cross strut has elongated holes to allow alignment of the pedal. 2. Screw the pedal (4) firmly onto the cross strut (3). 3.
Set-up instructions 7.8 Inserting the machine head Figure 56: Inserting the machine head 2 1 (1) - Rubber inlays (2) - Hinge upper parts WARNING Risk of crushing. The machine head is heavy. Take care not to jam your hands when fitting the machine head. This especially applies when fitting the hinge upper parts into the rubber inlays. 1. Screw the upper hinge parts (2) onto the machine head. 2. Fit the machine head from above at an angle of 45°. 3.
Set-up instructions 7.9 Fitting the oil extraction line Figure 57: Fitting the oil extraction line 1 2 (1) - Tube of the oil extraction line (2) - Filter 1. Fold the machine head back. 2. Screw the filter (2) into the oil pan with the plastic adapter to the right. 3. Insert the tube of the oil extraction line (1) into the plastic adapter. 86 Operating instructions 867 - 02.
Set-up instructions 7.10 Fitting the knee lever The machine has either a mechanical or electrical knee lever, depending on the subclass and equipment. 7.10.1 Fitting the mechanical knee lever Figure 58: Fitting the mechanical knee lever 3 1 (1) - Knee lever rod 1. 2. 3. 4. 2 (2) - Hole in the oil pan (3) - Transmission rod Fold the machine head back. Fit the transmission rod (3) in the oil pan. Screw the knee lever (1) rods together.
Set-up instructions 7.10.2 Fitting the electric knee lever Figure 59: Fitting the electric knee lever 1 2 3 (1) - Knee switch (2) - Connecting cable (3) - Plug 1. Screw the knee lever (1) in front of the oil pan firmly in place under the table plate. 2. Guide the connecting cable (2) to the back between the oil pan and the control. 3. Insert the plug (3) of the connecting cable in the socket of the control. 88 Operating instructions 867 - 02.
Set-up instructions 7.11 Fitting the control panel Figure 60: Fitting the control panel – Part 1 5 1 4 2 3 (1) - Upper machine cover (2) - Valve cover (3) - Cable duct (long arm only) (4) - Control panel bracket (5) - Control panel 1. Unscrew the valve cover (2) and upper machine cover (1). 2. Screw the control panel (5) firmly onto the control panel bracket (4). Long arm Additional step for long arm machines: machines 3. Install the connecting cable through the cable duct (3).
Set-up instructions 7.12 Electrical connection DANGER Danger to life due to electric shock. The machine may only be connected by trained electrical specialists. Disconnect the power plug before carrying out work on the electrical equipment. Make sure the power plug cannot be unintentionally reinserted. The voltage on the type plate of the sewing drive must correspond to the mains voltage. 7.12.
Set-up instructions Fitting the sewing lamp 1. Unscrew the valve cover and upper machine cover ( Section 7.11 Fitting the control panel, Page 89). The upper machine cover has pre-drilled holes for attaching the sewing lamp. Figure 62: Fitting the sewing lamp 1 2 (1) - Large hole (2) - 2 small holes 2. Either drill through the hole for 1 large hole (1) or through the holes for 2 small holes (2). 3. Screw the sewing lamp holder through the hole on the arm cover. 4. Fit the sewing lamp on the bracket. 5.
Set-up instructions Fitting the sewing lamp transformer Figure 63: Fitting the sewing lamp transformer 1 2 (1) - Sewing lamp transformer (2) - Pre-drilled holes 1. Screw the sewing lamp transformer (1) in place at the predrilled holes (2) under the table plate. 2. Fasten the connecting cable under the table plate using cable ties. 3. Establish the plug connection to the supply line for the sewing lamp.
Set-up instructions Connecting the sewing lamp transformer to the Efka controller Figure 65: Connecting the sewing lamp transformer to the Efka controller 1 2 3 4 5 (1) - Cable duct (2) - Rubber guide (3) - Upper clamp (4) - Lower clamp (5) - Clamp opening 1. Remove all 4 screws from the controller front panel. 2. Remove the front panel. 3. Feed the cable from the rear through the cable duct (1) into the controller. 4. Remove the black rubber guide (2). 5.
Set-up instructions 7.12.3 Establishing equipotential bonding DANGER Danger to life due to electric shock. Disconnect the power plug before establishing equipotential bonding. Make sure the power plug cannot be unintentionally reinserted. The earthing cable conducts away any static charging of the machine head. Figure 66: Establishing equipotential bonding 1 (1) - Connection at the controller 2 (2) - Tab connector 1. Tilt the machine head. 2.
Set-up instructions 7.12.4 Connecting the controller DANGER Danger to life due to electric shock. Disconnect the power plug before connecting the controller. Make sure the power plug cannot be unintentionally reinserted. Connecting the controller consists of the following work: • • Insert the plugs of all connecting cables in the sockets on the back of the control. Connect the control to the power supply using the power cable.
Set-up instructions 7.12.5 Connecting the sewing machine head 3. Insert the plug on the connecting cable for the sewing machine head into the socket of the respective controller. The connection diagram is provided in the Operating manual for the respective controller: • Efka DC1550/DA321G controller: The operating manual is provided in the controller accessory pack. • DAC ECO and DAC CLASSIC controllers: The operating manual is provided in the controller accessory pack.
Set-up instructions Fitting the Hall sensor 1. Remove the handwheel and handwheel cover. 2. Remove the valve cover. Figure 68: Fitting the Hall sensor 1 4 2 (1) - Magnet (2) - Belt pulley 3 (3) - Pre-drilled holes (4) - Cable opening 3. Fit the Hall sensor to the pre-drilled holes (3). 4. Feed the Hall sensor cable through the cable opening (4) down to the controller 5. Check if a magnet is already fitted to the pulley wheel (2).
Set-up instructions Efka controller Additional step for Efka controllers: 7. Check and set the following parameters: • F-290 as per Parameter sheet 9800 331104 PBXX • F-111 set to 3,000 RPM or less • F-270 set to 6 (position sensor selection) • F-272 to be calculated according to the following formula: Motor belt pulley diameter (teeth) Machine belt pulley diameter (teeth) x 1000 With DAC controllers the parameters are automatically set via transfer of the machine ID. 8.
Set-up instructions 7.12.7 Connecting the electrical knee switch Figure 69: Connecting the knee switch 1 3 2 (1) - Earth connection on the rear side of the controller (2) - DAC controller connection socket: Rear side (3) - Efka controller connection socket: Front side 1. Connect the knee switch earthing cable to the rear side of the controller (1). 2.
Set-up instructions 7.12.8 Fitting the M-Control circuit board DANGER Danger to life due to electric shock. Disconnect the power plug before fitting the circuit board. Make sure the power plug cannot be unintentionally reinserted. Figure 70: Fitting the circuit board 1 3 2 (1) - Frame (2) - Cable duct (3) - Setpoint device angle bracket 1.
Set-up instructions Figure 71: Connecting the circuit board 4 3 1 2 (1) - Upper section compressed air hoses (2) - Compressed air supply hose (3) - Connection sockets 2. Connect the compressed air supply hose (2) to the maintenance unit. 3. Fasten the upper section compressed air hoses (1) to the throttle valves (4).
Set-up instructions 7.12.9 Setting machine-specific parameters With DAC controllers the parameters are automatically set via transfer of the machine ID. With Efka controllers the parameter F-290 must be set for each subclass according to the specifications in Parameter sheet. The parameter sheet is provided in the controller accessory pack. 1. Set parameter F-290 according to the specifications in Parameter sheet. For subclass 867-290342-100 only: 2. Set parameter F-111 to 2500 min-1 or less.
Set-up instructions 7.13 Pneumatic connection 7.13.1 Fitting the maintenance unit The pneumatic connection package is available under order number 0797 003031. It consists of: • System connection hose (length 5 m, diameter 9 mm) Hose connectors and hose clamps Coupling socket and coupling plug • • Correct setting The system pressure for the pneumatic unit is 8 – 10 bar. ATTENTION Machine damage possible due to incorrect pressure. An incorrect pressure can cause damage to the machine.
Set-up instructions 7.13.2 Setting the operating pressure Correct setting The operating pressure for the pneumatic unit is 6 bar. ATTENTION Machine damage possible due to incorrect pressure. An incorrect pressure can cause damage to the machine. Make sure that the operating pressure is set correctly before putting the machine into operation. Figure 74: Setting the operating pressure 1 6 4 8 2 10 0 2 (1) - Turning handle (2) - Pressure indicator 1. Pull the turning handle (1) up. 2.
Set-up instructions 7.14 Lubrication WARNING Skin injuries due to contact with oil. Oil can cause a rash if it comes into contact with the skin. Avoid any skin contact with the oil. If oil gets on your skin, wash the affected skin areas thoroughly. All wicks and felt bits of the machine head are soaked in oil on delivery. This oil is conveyed to the reservoir during use. which is why you should avoid filling too much oil during initial filling.
Set-up instructions Oil to be used: Only DA 10 or an oil of equivalent quality may be used for the machine, which has the following properties: • • Viscosity at 40° C: 10 mm²/s Flash point: 150 °C ATTENTION Machine damage possible due to incorrect oil. An incorrect oil type can cause damage to the machine. Only use oil that complies with the data in the operating manual. ENVIRONMENTAL Risk of environmental damage from oil. Oil is a pollutant and must not enter the sewage system or the soil.
Set-up instructions 7.15 Sewing text Carry out a sewing test before starting up the machine. Adjust the machine to the requirements of the material to be sewn. To do this, read the corresponding chapters of the Operating instructions. Read the corresponding chapter of the Service instructions in order to make adjustments to the machine if the sewing results do not conform the to the requirements. WARNING Risk of injury by the needle point and moving parts.
Set-up instructions 108 Operating instructions 867 - 02.
Disposal 8 Disposal The customer is responsible for disposal of the machine and packaging materials. The respectively applicable legal regulations must be observed for disposal. Operating instructions 867 - 02.
Disposal 110 Operating instructions 867 - 02.
Appendix 9 Appendix 9.1 Table plate drawings Dimensions for manufacturing a tabletop, part 1 Operating instructions 867 - 02.
Appendix Dimensions for manufacturing a tabletop, part 2 112 Operating instructions 867 - 02.
Appendix Dimensions for manufacturing a tabletop, part 2 Operating instructions 867 - 02.
114 Stitch length 9–12 Stitch length 6–9 Stitch length 0–6 2500 1800 Stroke 5 Stroke 6-9 1800 3000 Stroke 1-4 Stroke 6-9 1800 2000 2500 Stroke 6-9 Stroke 1-5 3000 Stroke 5 260122 Stroke 1-4 867- Stitch length Stroke 1-5 9–12 Stroke 6-9 Stitch length Stroke 5 6–9 Stroke 6-9 Stroke 1-4 2000 1800 2000 1800 1800 2000 1800 2500 3000 1800 2000 1800 2500 3000 1800 2000 1800 2500 3000 1800 2000 1800 2500 3000 1800 2000 1800 2500 3000 1800 2000 1800 2500 3000 1
Operating instructions 867 - 02.
Appendix 116 Operating instructions 867 - 02.
Subject to design changes - Printed in Germany - © Dürkopp Adler AG - Original Instructions - 0791 867750 EN - 02.0 - 08/2015 DÜRKOPP ADLER AG Potsdamer Str. 190 33719 Bielefeld Germany Phone +49 (0) 521 925 00 E-Mail: service@duerkopp-adler.com www.duerkopp-adler.
