Dürkopp Adler D867 e-con Operating instructions

Service Instructions
D867 e-con

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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 2023
IMPORTANT
READ CAREFULLY BEFORE USE
KEEP FOR FUTURE REFERENCE

Table of Contents
Service Instructions D867 e-con - 00.0 - 08/2023 1
1 About these instructions ........................................................... 5
1.1 For whom are these instructions intended?.................................. 5
1.2 Representation conventions – symbols and characters ............... 5
1.3 Other documents .......................................................................... 7
1.4 Liability.......................................................................................... 8
2 Safety........................................................................................... 9
2.1 Basic safety instructions ............................................................... 9
2.2 Signal words and symbols used in warnings.............................. 10
3 Working basis ........................................................................... 13
3.1 Order of the adjustments ............................................................ 13
3.2 Laying the cables........................................................................ 13
3.3 Calling up the service routine ..................................................... 14
3.4 Disassembling and assembling the covers................................. 17
3.4.1 Tilting the machine head ............................................................ 18
3.4.2 Disassembling and assembling the arm cover ........................... 19
3.4.3 Disassembling and assembling the front cover (service cover).. 20
3.4.4 Disassembling and assembling the head cover ......................... 21
3.4.5 Disassembling and assembling the motor cover ........................ 22
3.4.6 Disassembling and assembling the toothed belt cover............... 23
3.4.7 Disassembling and assembling the thread tension plate............ 26
3.4.8 Opening and closing the throat plate slide ................................. 28
3.5 Disassembling and assembling the throat plate ......................... 29
3.6 Disassembling and assembling the feed dog ............................. 30
3.7 Flats on shafts ............................................................................ 31
3.8 Locking the machine in place ..................................................... 32
3.9 Adjusting the handwheel into position ........................................ 33
4 Positioning the arm shaft crank on the arm shaft................. 35
5 Performing the basic settings of the eccentrics.................... 36
5.1 Adjusting the sewing foot stroke, feed dog lift and feed dog
movement of the eccentrics........................................................ 36
5.2 Adjusting the compensating weight ............................................ 40
6 Adjusting the mechanical stitch adjustment ......................... 41
6.1 Presetting the stitch regulator gear mechanically....................... 41
6.2 Adjusting the forward and backward stitch ................................. 43
7 Adjusting feed dog and needle bar linkage ........................... 44
7.1 Adjusting the lateral feed dog position........................................ 45
7.2 Moving the feed dog carrier sideways ........................................ 46
7.3 Aligning the needle bar linkage sideways................................... 47
7.4 Aligning the needle bar linkage in the sewing direction.............. 49
7.5 Aligning the feed dog in sewing direction ................................... 50
7.6 Adjusting the feed dog height at top dead center ....................... 51
8 Position of the hook and needle ............................................. 52
8.1 Adjusting the hook side clearance.............................................. 53
8.2 Adjusting the looping stroke position .......................................... 54
8.3 Adjusting the needle bar height .................................................. 57
8.4 Adjusting the needle guard......................................................... 58

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2Service Instructions D867 e-con - 00.0 - 08/2023
9 Adjusting the bobbin case lifter.............................................. 60
9.1 Adjusting the lifting gap .............................................................. 61
9.2 Adjusting the timing for lifting...................................................... 62
10 Sewing feet................................................................................ 63
10.1 Adjusting the sewing foot lifting gear .......................................... 63
10.2 Adjusting an even sewing foot stroke ......................................... 67
10.3 Adjusting the sewing foot pressure and sewing foot lift.............. 68
11 Adjusting the needle thread tension....................................... 71
11.1 Adjusting the needle thread regulator......................................... 71
11.2 Adjusting the thread tensioning spring ....................................... 73
11.2.1 Adjusting the spring travel .......................................................... 73
11.2.2 Adjusting the spring tension ....................................................... 74
12 Bobbin winder........................................................................... 75
12.1 Adjusting the winder to a bobbin diameter ................................. 75
12.2 Adjusting the winder filling quantity ............................................ 76
12.3 Adjusting the bobbin thread guide .............................................. 77
13 Thread trimmer (FA) ................................................................. 78
13.1 Adjusting the height of the thread-pulling knife........................... 78
13.2 Adjusting the cutoff curve ........................................................... 79
13.3 Adjusting the cutting pressure .................................................... 82
13.4 Adjusting point in time for cutting................................................ 83
14 Short thread trimmer (KFA) ..................................................... 85
14.1 Adjusting the height and initial position of the
thread-pulling knife ..................................................................... 86
14.2 Adjusting the locking latch .......................................................... 88
14.3 Adjusting the control cam sideways ........................................... 89
14.4 Adjusting the bobbin case support ............................................. 90
14.5 Adjusting the cutting pressure .................................................... 91
14.6 Adjusting point in time for cutting................................................ 92
15 Long thread trimmer (LFA) ...................................................... 94
15.1 Adjusting the height of the thread-pulling knife........................... 94
15.2 Adjusting the cutoff curve ........................................................... 95
15.3 Adjusting the cutting pressure .................................................... 97
15.4 Adjusting point in time for cutting................................................ 98
16 Adjusting the safety release clutch ...................................... 100
16.1 Engaging the safety release clutch........................................... 100
16.2 Adjusting the torque.................................................................. 102
17 Toothed belt ............................................................................ 103
17.1 Changing the upper toothed belt .............................................. 103
17.2 Changing the lower toothed belt............................................... 104
18 Sewing motor .......................................................................... 109
18.1 Overview of the components .................................................... 109
18.2 Disassembling the sewing motor.............................................. 110

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Service Instructions D867 e-con - 00.0 - 08/2023 3
18.3 Assembling the sewing motor................................................... 112
19 Programming .......................................................................... 117
19.1 Logging in as a technician ........................................................ 117
19.2 Log in user................................................................................ 118
19.2.1 Logging in with username and password ................................. 119
19.2.2 Logging with NFC tag (optional) ............................................... 119
19.2.3 Login with USB key .................................................................. 120
19.2.4 Login with file on USB key........................................................ 121
19.3 Defining general settings (technician access) .......................... 123
19.4 Setting the Machine Configuration .................................. 125
19.4.1 Setting the Thread trimmer parameters .............................. 127
19.4.2 Setting the Needle thread clamp parameters ................... 131
19.4.3 Setting the Sewing speed parameters .................................. 133
19.4.4 Setting the Stop Positions parameters .............................. 134
19.4.5 Setting the Sewing foot lift parameters.......................... 135
19.4.6 Setting the Needle thread tension parameters ............... 135
19.4.7 Setting the Sewing foot stroke parameters ..................... 137
19.4.8 Setting the Stitch length parameters ................................ 139
19.4.9 Setting the RFW/SSD parameters ............................................. 141
19.4.10 Setting the Needle thread monitor parameters ............. 142
19.4.11 Setting the Needle thread tension sensor
parameters ............................................................................... 144
19.4.12 Setting the Holding Force parameters .............................. 144
19.4.13 Setting the Pedal parameters................................................ 145
19.4.14 Setting the Pedal 2 parameters ........................................... 145
19.4.15 Setting the Needle Cooling parameters ............................ 146
19.4.16 Setting the Puller parameters ............................................. 147
19.4.17 Setting the Edge Guide parameters..................................... 150
19.4.18 Setting the Material thickness detection
parameters ............................................................................... 151
19.4.19 Setting the Correction speed effect parameters......... 152
19.4.20 Setting the Light barrier parameters .............................. 152
19.4.21 Setting the Seam segment mode parameters...................... 153
19.4.22 Setting the Threading mode parameters ............................ 153
19.4.23 Setting the Operation lock parameters ............................ 153
19.4.24 Setting the Manual bartack parameters ............................ 154
19.4.25 Setting the Jog-Dial parameters ......................................... 154
19.4.26 Setting the Referencing parameters................................... 154
19.4.27 Setting the Function modules parameter.......................... 155
19.4.28 Setting the Scanner parameters ........................................... 155
19.4.29 Setting the RFID scanner parameters................................. 156
19.4.30 Setting the Desk height adjustment parameters........... 156
19.4.31 Setting the Interface parameters....................................... 156
19.4.32 Setting the Module management parameters...................... 157
19.4.33 Setting the Authentication methods parameters........... 161
19.4.34 Setting the Energy Saving parameter ................................ 161
19.5 Setting the Program defaults ............................................. 162
19.6 Setting the User Configuration......................................... 163
19.6.1 User Management .................................................................... 165
19.6.2 Smart keys configuration .......................................................... 171
19.6.3 Role Main Screen Configuration............................................... 171

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4Service Instructions D867 e-con - 00.0 - 08/2023
19.6.4 Role Status Bar Configuration .................................................. 172
19.7 Using Manual Data Transfer ............................................ 173
19.7.1 Exporting data .......................................................................... 173
19.7.2 Importing data........................................................................... 177
19.8 Service................................................................................... 180
19.8.1 Calibration .......................................................................... 181
19.8.2 Settings ................................................................................ 187
19.8.3 Multi test ............................................................................ 188
19.8.4 Maintenance Management .................................................. 192
19.8.5 QONDAC..................................................................................... 195
19.8.6 Reset....................................................................................... 196
19.8.7 Network................................................................................... 197
19.8.8 Logging................................................................................... 197
19.8.9 Logger modules........................................................................ 198
19.9 Information .......................................................................... 200
19.10 Performing a software update........................................... 203
20 Maintenance............................................................................ 205
20.1 Cleaning ................................................................................... 206
20.2 Lubricating ................................................................................ 207
20.2.1 Lubricating the machine head .................................................. 208
20.2.2 Lubricating the hook ................................................................. 209
20.3 Servicing the pneumatic system (optional)............................... 210
20.3.1 Adjusting the operating pressure.............................................. 210
20.3.2 Draining the water-oil mixture................................................... 211
20.3.3 Cleaning the filter element........................................................ 212
20.4 Servicing specific components ................................................. 213
20.4.1 Cleaning the thread clamp........................................................ 213
20.4.2 Performing the basic settings of the hook support ................... 215
20.5 Parts list.................................................................................... 216
21 Decommissioning................................................................... 217
22 Disposal................................................................................... 219
23 Troubleshooting ..................................................................... 221
23.1 Customer Service ..................................................................... 221
23.2 Messages of the software......................................................... 221
23.3 Errors in sewing process .......................................................... 241
24 Technical data......................................................................... 243
24.1 Data and characteristic values ................................................ 244
24.2 Requirements for fault-free operation....................................... 244
25 Appendix ................................................................................. 245
25.1 Barcode examples.................................................................... 245
25.2 Converting videos for playback on the control panel................ 246
25.3 Basic settings of the machine................................................... 249
25.4 Wiring diagram ......................................................................... 250

About these instructions
Service Instructions D867 e-con - 00.0 - 08/2023 5
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
Service (p. 221).
Consider the instructions as part of the product and store them in a place
where they are readily available.
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. 9).
1.2 Representation conventions – symbols and characters
Various information in these instructions are 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 setting.
Cover
Specifies which covers must be disassembled in order to access the
components to be set.

About these instructions
6Service Instructions D867 e-con - 00.0 - 08/2023
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
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 a setting.
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. 9).
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 D867 e-con - 00.0 - 08/2023 7
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.

About these instructions
8Service Instructions D867 e-con - 00.0 - 08/2023
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 damage was discovered. This will ensure
any claims against the transport company.
Report all other complaints to Dürkopp Adler immediately after receiving
the product.

Safety
Service Instructions D867 e-con - 00.0 - 08/2023 9
2 Safety
This chapter contains basic information for your safety. Read the instructions
carefully before setting up or operating the machine. Be sure to follow the
information in the safety instructions. 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 ma-
chine 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 the legal regulations concerning industrial safety and the protection
of the environment.
All the warnings and safety signs on the machine must always be in legible
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 be used for:
• Setting up the machine/putting the machine into operation
• 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
10 Service Instructions D867 e-con - 00.0 - 08/2023
Operation Check the machine during operating for any externally visible damage.
Stop working if you notice any changes to the machine. Report any
changes 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
Icon Type of danger
General
Electric shock

Safety
Service Instructions D867 e-con - 00.0 - 08/2023 11
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
serious 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
Icon 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
12 Service Instructions D867 e-con - 00.0 - 08/2023
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 D867 e-con - 00.0 - 08/2023 13
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 cables
Ensure that all cables are laid in the machine such that the function of
moving parts is not hampered.
To lay the cables:
1. Lay any excess cables 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 cables can impair the functioning of moving machine parts.
This impairs the sewing function and can result in damage.
Lay excess cables as described above.

Working basis
14 Service Instructions D867 e-con - 00.0 - 08/2023
3.3 Calling up the service routine
The machine must remain switched on for the following settings,
as switching off will delete the required programmed values:
• Disassembling and assembling the feed dog
• Adjusting the feed dog
• Adjusting the feed dog feed movement
• Aligning the needle bar linkage
• Adjusting the loop stroke position
• Adjusting the needle bar height
• Adjusting an even sewing foot stroke
• Adjusting the feeding foot movement
Call up the corresponding service routine to be able to make settings
on the active machine without any risk. In the service routine, the machine
moves to the correct position and the power is switched off as soon as
the Service Stop button is pressed. The settings are preprogrammed and
changes are not possible.
To activate the service routine:
1. Switch on the machine.
2. Log in as a technician (p. 117).
3. Select the required service routine in the menu Navigation >
Adjustments > Service > Adjustments.
The display shows all the values set in the selected service routine.
Settings
Feed dog Assemble (disassembling and assembling the feed dog)
Position to needle (adjusting the feed dog)
Feed dog movement (setting the feed dog feed movement)
Hook-Needle Timing (setting the looping stroke position)
Needle bar (adjusting the needle bar)
Sewing foot
stroke
Equal sewing foot stroke (setting an even sewing foot stroke)
Feed Move (setting the feeding foot movement)

Working basis
Service Instructions D867 e-con - 00.0 - 08/2023 15
Fig. 1: Calling up the service routine (1)
4. Press Next.
A request appears to press the Service Stop button.
Fig. 2: Calling up the service routine (2)
5. Press the Service Stop button.
The machine moves to the programmed position and is switched off.
The button lights up.
The display shows the information that the Service Stop is active:
Fig. 3: Calling up the service routine (3)
6. Make the required settings.

Working basis
16 Service Instructions D867 e-con - 00.0 - 08/2023
7. Press Next.
A request appears on the display to deactivate the Service Stop:
Fig. 4: Calling up the service routine (4)
8. Press the Service Stop button.
The power is switched on again.
The button turns off.
Fig. 5: Calling up the service routine (5)
9. Press Finish.
You are now in the service menu again.
10. Press the button.
The machine moves back to its initial position and is ready to sew.

Working basis
Service Instructions D867 e-con - 00.0 - 08/2023 17
3.4 Disassembling and assembling the covers
For many types of adjustment work, you will have to disassemble the
machine covers first in order to access the components.
This chapter describes how to disassemble and then assemble the
individual covers again. The text for each type of adjustment work then
specifies only the cover that needs to be disassembled at that particular
time.
Information
Always apply 1Nmof tightening torque when tightening the screws that
are used to attach the covers.
WARNING
Risk of injury from moving parts!
Crushing possible.
Move the machine to the service position or switch
the machine off before disassembling the covers.
WARNING
Risk of injury from sharp parts!
Puncture possible.
Move the machine to the service position or switch
the machine off before disassembling the covers.

Working basis
18 Service Instructions D867 e-con - 00.0 - 08/2023
3.4.1 Tilting the machine head
Cover
In order to access the components on the underside of the machine, you
must first tilt the machine head.
Fig. 6: Access to the underside of the machine
Tilting the machine head
To tilt the machine head:
1. Tilt the machine head as far as it will go.
Erecting the machine head
To erect the machine head:
1. Push the locking mechanism (1) up with one hand.
2. Erect the machine head using your other hand.
(1) - Locking mechanism
①