Dürkopp Adler D869 e-con Operating instructions

D869 e-con
Service Instructions

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Property of Dürkopp Adler GmbH and protected by copyright. Any reuse of these contents,
including extracts, is prohibited without the prior written approval of Dürkopp Adler GmbH.
Copyright © Dürkopp Adler GmbH 2023
IMPORTANT
READ CAREFULLY BEFORE USE
KEEP FOR FUTURE REFERENCE

Table of Contents
Service Instructions D869 e-con - 00.0 - 09/2023 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.......... 25
3.4.8 Disassembling and assembling the throat plate slide............... 27
3.4.9 Disassembling and assembling the throat plate ....................... 28
3.5 Disassembling and assembling the feed dog ........................... 30
3.6 Flats on shafts .......................................................................... 32
3.7 Locking the machine in place ................................................... 34
3.8 Adjusting the handwheel into position ...................................... 35
4 Positioning the arm shaft crank on the arm shaft ............... 37
5 Performing the basic settings of the eccentrics.................. 38
5.1 Adjusting the sewing foot stroke, feed dog lift and feed dog
movement of the eccentric........................................................ 38
5.2 Adjusting the compensating weight .......................................... 43
6 Adjusting the mechanical stitch adjustment ....................... 44
6.1 Presetting the stitch regulator gear mechanically ..................... 44
6.2 Adjusting the forward and backward stitch ............................... 46
7 Adjusting feed dog and needle bar linkage ......................... 47
7.1 Adjusting the feed dog position................................................. 47
7.2 Aligning the needle bar linkage sideways................................. 49
7.3 Aligning the needle bar linkage in the sewing direction ............ 51
7.4 Adjusting the feed dog height at top dead center ..................... 52
8 Position of the hook and needle ........................................... 53
8.1 Adjusting the hook side clearance............................................ 53
8.2 Adjusting the looping stroke position ........................................ 56
8.3 Adjusting the needle guard ....................................................... 57
8.4 Adjusting the needle bar height ................................................ 58
9 Adjusting the bobbin case lifter ............................................ 60

Inhaltsverzeichnis
2Service Instructions D869 e-con - 00.0 - 09/2023
10 Sewing feet.............................................................................. 62
10.1 Adjusting the sewing foot lifting gear ........................................ 62
10.2 Adjusting an even sewing foot stroke ....................................... 66
10.3 Adjusting the sewing foot pressure and sewing foot lift ............ 67
11 Adjusting the needle thread tension..................................... 70
11.1 Adjusting the needle thread regulator....................................... 70
11.2 Adjusting the thread tensioning spring...................................... 72
11.2.1 Adjusting the spring travel ........................................................ 72
11.2.2 Adjusting the spring tension...................................................... 74
12 Bobbin winder......................................................................... 78
12.1 Adjusting the winder to a bobbin diameter................................ 78
12.2 Adjusting the winder filling quantity........................................... 79
12.3 Adjusting the bobbin thread guide ............................................ 80
13 Thread trimmer ....................................................................... 81
13.1 Adjusting the height of the thread-pulling knife......................... 81
13.2 Adjusting the cutoff curve ......................................................... 82
13.3 Adjusting the cutting pressure .................................................. 84
13.4 Adjusting point in time for cutting.............................................. 85
14 Adjusting the safety release clutch ...................................... 87
14.1 Engaging the safety release clutch........................................... 87
14.2 Adjusting the torque.................................................................. 88
15 Toothed belt ............................................................................ 89
15.1 Changing the upper toothed belt .............................................. 89
16 Sewing motor .......................................................................... 94
16.1 Overview of the components .................................................... 94
16.2 Disassembling the sewing motor .............................................. 94
16.3 Assembling the sewing motor................................................... 99
17 Programming ........................................................................ 105
17.1 Logging in as a technician ...................................................... 105
17.2 Log in user .............................................................................. 106
17.2.1 Logging in with username and password ............................... 107
17.2.2 Login with NFC tag (optional) ................................................. 107
17.2.3 Login with USB key................................................................. 108
17.2.4 Login with file on USB key ...................................................... 109
17.3 Defining general settings (technician access) ........................ 111
17.4 Setting the Machine Configuration ................................ 113
17.4.1 Setting the Thread trimmer parameters ............................ 115
17.4.2 Setting the Needle thread clamp parameters ................. 119
17.4.3 Setting the Sewing speed parameters................................. 121
17.4.4 Setting the Stop Positions parameters ............................ 122
17.4.5 Setting the Sewing foot lift parameters........................ 123
17.4.6 Setting the Needle thread tension parameters ............. 123
17.4.7 Setting the Sewing foot stroke parameters.................... 125
17.4.8 Setting the Stitch length parameters .............................. 127
17.4.9 Setting the RFW/SSD parameters ........................................... 129

Table of Contents
Service Instructions D869 e-con - 00.0 - 09/2023 3
17.4.10 Setting the Needle thread monitor parameters ............ 130
17.4.11 Setting the Needle thread tension sensor
parameters.............................................................................. 132
17.4.12 Setting the Holding Force parameters ............................. 132
17.4.13 Setting the Pedal parameters............................................... 133
17.4.14 Setting the Pedal 2 parameters ......................................... 133
17.4.15 Setting the Needle Cooling parameters ........................... 134
17.4.16 Setting the Puller parameters ............................................ 135
17.4.17 Setting the Edge Guide parameters.................................... 138
17.4.18 Setting the Material thickness detection
parameters.............................................................................. 139
17.4.19 Setting the Correction speed effect parameters........ 140
17.4.20 Setting the Light barrier parameters ............................. 140
17.4.21 Setting the Seam segment mode parameters..................... 141
17.4.22 Setting the Threading mode parameters ........................... 141
17.4.23 Setting the Operation lock parameters ........................... 141
17.4.24 Setting the Manual bartack parameters ........................... 142
17.4.25 Setting the Jog-Dial parameters ........................................ 142
17.4.26 Setting the Referencing parameters.................................. 142
17.4.27 Setting the Function modules parameter......................... 143
17.4.28 Setting the Scanner parameters ........................................... 143
17.4.29 Setting the RFID Scanner parameters................................ 144
17.4.30 Setting the Desk height adjustment parameters.......... 144
17.4.31 Setting the Interface parameters ...................................... 145
17.4.32 Setting the Module management parameters..................... 145
17.4.33 Setting the Authentication methods parameters.......... 149
17.4.34 Setting the Energy Saving parameter ............................... 149
17.5 Setting the Program defaults ........................................... 150
17.6 Setting the User Configuration....................................... 151
17.6.1 User Management .................................................................. 153
17.6.2 Smart keys configuration ........................................................ 158
17.6.3 Role Main Screen Configuration............................................. 159
17.6.4 Role Status Bar Configuration ................................................ 160
17.7 Using Manual Data Transfer .......................................... 161
17.7.1 Exporting data......................................................................... 161
17.7.2 Importing data......................................................................... 165
17.8 Service................................................................................. 168
17.8.1 Calibration ........................................................................ 169
17.8.2 Settings............................................................................... 175
17.8.3 Multi test .......................................................................... 176
17.8.4 Maintenance Management ................................................ 180
17.8.5 QONDAC................................................................................... 183
17.8.6 Reset ..................................................................................... 184
17.8.7 Network................................................................................. 185
17.8.8 Logging................................................................................. 185
17.8.9 Logger modules ...................................................................... 186
17.9 Information ........................................................................ 188
17.10 Performing a software update.......................................... 190
18 Maintenance .......................................................................... 191
18.1 Cleaning.................................................................................. 192
18.2 Lubricating .............................................................................. 193

Inhaltsverzeichnis
4Service Instructions D869 e-con - 00.0 - 09/2023
18.2.1 Lubricating the machine head................................................. 194
18.2.2 Lubricating the hook ............................................................... 195
18.3 Servicing the pneumatic system (optional) ............................. 195
18.3.1 Adjusting the operating pressure ............................................ 195
18.3.2 Draining the water-oil mixture ................................................. 196
18.3.3 Cleaning the filter element ...................................................... 197
18.4 Servicing specific components ............................................... 199
18.4.1 Cleaning the thread clamp...................................................... 199
18.5 Parts list .................................................................................. 200
19 Decommissioning................................................................. 201
20 Disposal................................................................................. 203
21 Troubleshooting ................................................................... 205
21.1 Customer Service ................................................................... 205
21.2 Messages of the software....................................................... 205
21.3 Errors in sewing process ........................................................ 225
22 Technical data....................................................................... 227
22.1 Data and characteristic values................................................ 227
22.2 Requirements for fault-free operation ..................................... 227
23 Appendix ............................................................................... 229
23.1 Barcode examples .................................................................. 229
23.2 Converting videos for playback on the control panel .............. 230
23.3 Basic settings of the machine ................................................. 233
23.4 Wiring diagram........................................................................ 234

About these instructions
Service Instructions D869 e-con - 00.0 - 09/2023 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. 205).
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 D869 e-con - 00.0 - 09/2023
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 D869 e-con - 00.0 - 09/2023 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
national regulations. The proper use of the built-in components is
described in the corresponding manufacturer's instructions.

About these instructions
8Service Instructions D869 e-con - 00.0 - 09/2023
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 D869 e-con - 00.0 - 09/2023 9
2 Safety
This chapter contains basic information for your safety. Read the instruc-
tions 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 machine
max. 20 mm and secure it to prevent it from slipping off.
Setup The connecting cable must have a power plug approved in the relevant
country. The power plug may only be assembled to the power cable by
qualified specialists.
Obligations
of the operator
Follow the country-specific safety and accident prevention regulations and
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 D869 e-con - 00.0 - 09/2023
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 essen-
tial 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 D869 e-con - 00.0 - 09/2023 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 D869 e-con - 00.0 - 09/2023
This is what a warning looks like for a hazard that could result in envi-
ronmental 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 D869 e-con - 00.0 - 09/2023 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 D869 e-con - 00.0 - 09/2023
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
• Setting the looping stroke position
• Adjusting the needle bar height
• Adjusting an even sewing foot stroke
• Setting 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. 105).
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 (assembling and removing 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 D869 e-con - 00.0 - 09/2023 15
Fig. 1: Calling up the service routine (1)
4. Press the button.
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)

Working basis
16 Service Instructions D869 e-con - 00.0 - 09/2023
6. Make the required settings.
7. Press the button.
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 the button.
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 D869 e-con - 00.0 - 09/2023 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 individ-
ual 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 D869 e-con - 00.0 - 09/2023
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. Lift the lever (3).
2. Tilt the machine head (1) as far as it will go.
Erecting the machine head
To erect the machine head:
1. Erect the machine head (1).
For safety reasons, the machine head (1) is stopped by the bolt (2).
2. Lift the lever (3) and erect the machine head (1) completely.
(1) - Machine head
(2) - Bartack
(3) - Lever
①
③
②