Duerkopp Adler 868 User manual

868
Special Sewing Machine
Instruction manual
Postfach 17 03 51, D-33703 Bielefeld • Potsdamer Straße 190, D-33719 Bielefeld
Telefon +49 (0) 521 / 9 25-00 • Telefax +49 (0) 521 / 9 25 24 35 • www.duerkopp-adler.com
Ausgabe / Edition: Änderungsindex Teile-Nr./Part.-No.:
03/2011 Rev. index: 00.0 Printed in Federal Republic of Germany 0791 868751

All rights reserved.
Property of Dürkopp Adler AG and copyrighted. Reproduction or publication of the content in any manner,
even in extracts, without prior written permission of Dürkopp Adler AG, is prohibited.
Copyright © Dürkopp Adler AG - 2011

Foreword
This instruction manual is intended to help the user to become familiar
with the machine and take advantage of its application possibilities in
accordance with the recommendations.
The instruction manual contains important information on how to
operate the machine securely, properly and economically. Observation
of the instructions eliminates danger, reduces costs for repair and
down-times, and increases the reliability and life of the machine.
The instruction manual is intended to complement existing national
accident prevention and environment protection regulations.
The instruction manual must always be available at the machine/sewing
unit.
The instruction manual must be read and applied by any person that is
authorized to work on the machine/sewing unit. This means:
–Operation, including equipping, troubleshooting during the work
cycle, removing of fabric waste,
–Service (maintenance, inspection, repair) and/or
–Transport.
The user also has to assure that only authorized personnel work on the
machine.
The user is obliged to check the machine at least once per shift for
apparent damages and to immediatly report any changes (including the
performance in service), which impair the safety.
The user company must ensure that the machine is only operated in
perfect working order.
Never remove or disable any safety devices.
If safety devices need to be removed for equipping, repairing or
maintaining, the safety devices must be remounted directly after
completion of the maintenance and repair work.
Unauthorized modification of the machine rules out liability of the
manufacturer for damage resulting from this.
Observe all safety and danger recommendations on the machine/unit!
The yellow-and-black striped surfaces designate permanend danger
areas, eg danger of squashing, cutting, shearing or collision.
Besides the recommendations in this instruction manual also observe
the general safety and accident prevention regulations!

General safety instructions
The non-observance of the following safety instructions can cause
bodily injuries or damages to the machine.
1. The machine must only be commissioned in full knowledge of the
instruction book and operated by persons with appropriate training.
2. Before putting into service also read the safety rules and
instructions of the motor supplier.
3. The machine must be used only for the purpose intended. Use of
the machine without the safety devices is not permitted. Observe all
the relevant safety regulations.
4. When gauge parts are exchanged (e.g. needle, presser foot, needle
plate, feed dog and bobbin) when threading, when the workplace is
left, and during service work, the machine must be disconnected
from the mains by switching off the master switch or disconnecting
the mains plug.
5. Daily servicing work must be carried out only by appropriately
trained persons.
6. Repairs, conversion and special maintenance work must only be
carried out by technicians or persons with appropriate training.
7. For service or repair work on pneumatic systems, disconnect the
machine from the compressed air supply system (max. 7-10 bar).
Before disconnecting, reduce the pressure of the maintenance unit.
Exceptions to this are only adjustments and functions checks made
by appropriately trained technicians.
8. Work on the electrical equipment must be carried out only by
electricians or appropriately trained persons.
9. Work on parts and systems under electric current is not permitted,
except as specified in regulations DIN VDE 0105.
10. Conversion or changes to the machine must be authorized by us
and made only in adherence to all safety regulations.
11. For repairs, only replacement parts approved by us must be used.
12. Commissioning of the sewing head is prohibited until such time as
the entire sewing unit is found to comply with EC directives.
13. The line cord should be equipped with a country-specific mains
plug. This work must be carried out by appropriately trained
technicians (see paragraph 8).
It is absolutely necessary to respect the safety
instructions marked by these signs.
Danger of bodily injuries !
Please note also the general safety instructions.

Contents Page:
Preface and general safety instructions
Part 1: Operating Instructions Class 868 – Original Instructions
(Edition 03/2011)
1 Product description ............................................ 5
2 Designated use ............................................... 5
3 Subclasses .................................................. 6
4 Optional equipment............................................. 8
5 Technical data
5.1 Technicaldatasubclasses......................................... 11
6 Operation
6.1 Threadingtheneedlethread........................................ 13
6.2 Adjustingtheneedle-threadtension................................... 15
6.2.1 Function of the thread main tension and the thread supplementary tension in relation
tothesewingfootlifting .......................................... 16
6.2.2 Reparationseamwiththreadtensionalwaysclosed ......................... 16
6.2.3 Function of the thread’s supplementary tension in relation to the stroke adjustment
andtheSpeedomat ............................................. 17
6.3 Openingthethreadtension......................................... 17
6.4 Shortstitch .................................................. 18
6.4.1 Shortstitchattheseambeginning.................................... 18
6.4.2 Shortstitchattheendofaseam..................................... 18
6.4.3 Shortstitchattheseambeginningandseamend........................... 18
6.5 Switching the supplementary tension on and off with machines without thread trimmer .... 19
6.6 Adjustingthethreadregulator....................................... 20
6.7 Winding on the hook thread ........................................ 21
6.8 Changing the hook-thread bobbin .................................... 22
6.9 Setting the hook thread tension ...................................... 23
6.10 Insertingandchangingtheneedlewithsingle-needlemachines.................. 24
6.11 Insertingandchangingtheneedlewithdouble-needlemachines.................. 25
6.12 Liftingthesewingfoot............................................ 26
6.13 Lockingthesewingfeetinliftedposition ................................ 27
6.14 Sewing-footpressure............................................ 27
6.15 Sewing-footstroke.............................................. 28
6.16 Settingthestitchlength........................................... 30
6.17 Keypadonthemachinearm........................................ 31
7 Sewing drive and operating panel ................................... 32
8Sewing..................................................... 33

Contents Page:
9 Maintenance
9.1 Cleaningandtesting............................................. 35
9.2 Lubrication................................................... 37
10 Optional equipment
10.1 Seamcenterguide.............................................. 38
10.2 Repair ..................................................... 39

1 Product description
The DÜRKOPP ADLER 868 is a special sewing machine for universal
use.
·It is a flatbed double-lockstitch machine with bottom feed, needle
feed and alternating upper foot feed.
·Depending on the subclass it comes as single or double needle
automat, with or without electromagnetic thread cutter, with or
without edge trimmer.
·Equipped with a large or oversized two-piece vertical hook.
·With a maximum of 20 mm fabric clearance when sewing feet are
lifted.
·A safety clutch prevents a changing of the hook setting or a hook
damage in the case of a thread deflection into the shuttle track.
·Automatic wick lubricating with an inspection glass on the arm for
machine and hook lubrication.
·Integrated winder.
2 Designated use
The 868 class is a sewing machine designed for sewing light to
medium-heavy material. Such material is generally made of textile
fibers, but it may also be leather. It is used in the clothing industry and
for domestic and motor-vehicle upholstery.
This special sewing machine can also be used to produce so-called
technical seams. In this case, however, the operator must assess the
possible dangers which may arise (with which DÜRKOPP ADLER AG
would be happy to assist), since such applications are on the one
hand relatively unusual and, on the other, so varied that no single set
of criteria can cover them all. The outcome of this assessment may
require appropriate safety measures to be taken.
Generally only dry material may be sewn with this machine. The
material may be no thicker than 10 mm when compressed by the
lowered sewing feet. The material may not contain any hard objects,
since if it does the machine may not be operated without an
eye-protection device. No such device is currently available.
The seam is generally produced with textile-fibre sewing thread of
gauge up to 11/3 NeB (cotton), 11/3 Nm (synthetic) or 11/4 Nm
(covering yarn).
Before using any other thread the possible dangers arising must be
assessed and appropriate safety measures taken if necessary.
5

This special sewing machine may be set up and operated only
in dry, well-maintained premises. If the sewing machine is used in
premises which are not dry and well-maintained it may be
necessary to take further precautions, which should be agreed upon in
advance (see EN 60204-31:1999).
As manufacturers of industrial sewing machines we proceed on the
assumption that personnel who work on our products will have
received training at least sufficient to acquaint them with all normal
operations and with any hazards which these may involve.
3 Subclasses
868-190020 Single-needle double-lockstitch post bed machine
with bottom feed, needle feed, alternating upper
foot feed and large hook.
867-290020 Double-needle double-lockstitch post bed machine
with bottom feed, needle feed, alternating upper
foot feed and large hook.
868-190322 Single-needle double-lockstitch post bed machine
with bottom feed, needle feed, alternating upper
foot feed, electro-pneumatic rapid stroke
adjustment with automatic speed limitation,
operated via knee lever, electro-magnetic thread
cutter, electro-pneumatic seam bartacking,
electro-pneumatic second stitch length and sewing
foot lifting. With large hook, with integrated sewing
lamp.
Function keys for: manually sewing backward,
needle high/low/single stitch, switching on/off of the
bartack, 2nd stitch length, switching on/off of the
supplementary thread tension .
868-290322 Double-needle double-lockstitch post bed machine
with bottom feed, needle feed, alternating upper
foot feed, electro-pneumatic rapid stroke
adjustment with automatic speed limitation,
operated via knee lever, electro-magnetic thread
cutter, electro-pneumatic seam bartacking,
electro-pneumatic second stitch length and sewing
foot lifting. With large hook, with integrated sewing
lamp.
Function keys for: manually sewing backward,
needle high/low /single stitch, switching on/off of
the bartack, 2nd stitch length, switching on/off of
the supplementary thread tension.
6

868-390322 Double-needle double-lockstitch post bed machine
with bottom feed, needle feed, alternating upper
foot feed, electro-pneumatic rapid stroke
adjustment with automatic speed limitation,
operated via knee lever, electro-magnetic thread
cutter, electro-pneumatic seam bartacking,
electro-pneumatic second stitch length and sewing
foot lifting. With large hook, with integrated sewing
lamp.
Left post.
Function keys for: manually sewing backward,
needle high/low /single stitch, switching on/off of
the bartack, 2nd stitch length, switching on/off of
the supplementary thread tension.
7

4 Optional equipments
For the 868 the following optional equipments are available:
Order No. Optional equipment Subclasses
868-190020 868-290020 868-190322 868-290322 868-390322
0867 590014 Electro-pneumatic needle cooler x
from the top
0867 590064 Pneumatic connection x x x x x
9780 000108 WE-8 maintenance unit for pneumatic
optional equipments x x o o o
9822 510003 Halogen sewing lamp x x x x x
9880 867100 Sewing lamp add-on kit x x x x x
0798 500088 Sewing lamp transformer x x x x x
9880 867103 Sewing lamp LED x x x x x
9880 867102 Integrated sewing lamp LEDs x x o o o
9850 001089 Power supply complete for x x o o o
integrated sewing lamp LEDs
N800 080001 Edge guide, swivelling x x
N800 080004 Roller stop x x
N800 080021 Edge guide, swivelling x x
N800 005650 Seam center guide x x
N800 005655 Seam center guide, swivelling x x
No. according Tape guide with tape-reel bracket x x
to the band size
9805 791113 USB memory key
for transferring data with the x x x x x
Efka control unit DA321G
0797 003031 Pneumatic connection package x x x x
0867 590354 Pneumatic sewing foot lifting x x
Stands
MG55 400364 Stand set MG 55-3 x x x x x
for motor fitting beneath the table,
with pedal
Table top size 1060 x 600 mm
MG55 400374 Stand set MG 55-3 x x x
for motor fixed on machine head,
with Pedal
Table top size 1060 x 600 mm
x = Optional equipment
o = Standard equipment
8