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:
Part 2: Installation Instructions Class 868
1 Scope of Delivery ............................................ 5
2 General and transport packing .................................... 5
3 Assembling the stand
3.1 Assemblingthestandcomponents(Standard)............................ 7
3.2 Assemblingthetableplate ....................................... 7
3.3 Settingtheworkingheight........................................ 8
4 Sewing drives
4.1 Drivecategory,typeanduse...................................... 9
4.2 Drive-packcomponents......................................... 9
4.3 Fittingthesewingdrive.......................................... 10
4.4 Fittingthepedal.............................................. 10
4.5 Fitting the sewing-drive control for machines with Efka DC 1550 / DA 321G ......... 11
4.6 Fittingthesetvalueinitiator....................................... 11
5 Assembling the machine head
5.1 Fittingthehingesonthemachinehead................................ 12
5.2 Fitting the direct drive (Efka DC 1550/DA321G) ........................... 13
5.3 Tensioning the toothed belt of the direct drive (Efka DC 1550/DA321G) ............ 13
5.4 Placingthesewingmachineheadonthestand........................... 14
5.5 FittingandtensioningtheV-belt.................................... 15
5.6 Fittingthebeltcover........................................... 16
5.7 Fittingtheoilsuctiontube........................................ 17
5.8 Attachingthekneelever......................................... 18
5.9 Fittingtheoperatingpanel........................................ 19
5.10 Fittingthesewinglamp(optionalequipment) ............................ 20
6 Electrical connection
6.1 General................................................... 22
6.2 Checking the mains voltage ....................................... 22
6.3 Connectingthesewingdrive ...................................... 22
6.3.1 Connectingtheclutchmotor...................................... 22
6.3.2 Connectingthedirect-currentpositioningactuator......................... 22
6.4 Earthing................................................... 23
6.5 Connectingthesewingdrivetothemains.............................. 24
6.6 Connectingthemachinehead ..................................... 24
6.7 Connectingthesewinglighttransformer(optionalequipment).................. 25
6.8 Connectingthedirectdrive....................................... 26
6.8.1 ConnectingtheHallsensor(optionalequipment).......................... 26
6.8.2 Attachingandconnectingthesewinglighttransformer(optionalequipment)......... 28

Contents Page:
6.8.3 Connection to the DA321G control unit ................................ 28
6.8.4 Connecting the sockets of the DA321G control unit ........................ 29
6.8.5 Connecting the DA321G control unit ................................. 29
6.8.6 Checking the direction of rotation of the sewing drive ....................... 30
6.8.7 Checking the positioning......................................... 30
6.8.8 Machine-specificparameters...................................... 31
6.9 Masterreset................................................. 31
7 Pneumatic connection
7.1 Pneumaticsewingfootlifting...................................... 33
8 Lubrication................................................. 34
9 Sewing test ................................................ 35

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1 Scope of Delivery
What items are supplied depends on your order.
Prior to setting up, please check that all the required parts are
present.
This description refers to a special sewing machine, of which all
individual components can completely be delivered by Dürkopp Adler
AG.
–1Machine head
Dürkopp Adler accessory set box with:
–2Reel stand
–Protection cover (not represented)
–9Oil tray
Set of electronic parts, depending on the order, for:
Machines with Efka DC 1550 / DA321G actuator
–5Efka control unit
–11 Operating panel
–3Cover
Machines with clutch motor
–Main switch
–Sewing-drive
–Belt guard
Optional equipment
–8Stand (optional)
–7Pedal and linkage (optional)
–4Table top (optional)
–10 Drawer (optional)
–Knee lever
–Pneumatic sewing foot lifting
2 General and transport packing
Caution:
The special sewing machine must be set up by trained specialist
personnel.
Transportation locks
If the special sewing machine you have bought is already set up, the
following transport packing must be removed:
–Safety straps and battens on the machine head, table and stand.
–Safety block and straps on the sewing drive.
5

Observe the punch-marks of the table plate!
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13
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9
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14
3,5x17 (x 6)
4,5x15 (x 4)
3,5x17 (x 2)
B8x35 (x 4)
3,9x15 (x 5)
15

3 Assembling the stand
3.1 Assembling the stand components (Standard)
–Assemble the individual stand components as shown in the
illustration.
–Adjust the set screws 8to insure the stability of the stand.
Make sure that the stand is safe by insuring that every single foot
of the stand touches the ground.
3.2 Assembling the table plate
For an optimal arrangement, please respect the corresponding table
top layout:
Stand Table top layout
MG55 400364 0791 868710
MG55 400374 0791 868710
–Screw the drawer 10 with its holders onto the left side underneath
the table plate.
–Screw the oil sump 7 under the table plate.
The three stops of the oil sink should be fitted against the table
opening.
–Screw the main switch 5* to the right side under the table plate.
–Screw the cable duct 4* behind the main switch 5 under the table
plate.
–Screw the holder 3 for the traction relief of the connecting cable
behind cable duct 4 under the table plate.
–Screw the sewing-lamp transformer 6 (optional equipment)
under the table plate.
–Fit the machine head support 13** into the bore hole of the table
top .
–Put the cap 15** into the bore hole of the table top.
–Place the hinge bottoms 12 for the machine head into the cutout
of the table plate 11 and tighten the screws.
–Insert the inclination support 14**.
–Insert the rubber corners 2.
–Attach the table plate 11 to the stand with woodscrews (B8 x 35)
(see sketch for position).
–Insert the yarn stand 1 into the bore hole in the table plate and
secure it with the nuts and washers. Fit and align the yarn reel and
unwinding holders. The yarn reel holder and the unwinding arm
must be vertically in line.
–Screw the holder for the oil-can 9 onto the left-hand stand brace
* Not applicable with sewing machines with direct drive.
** If the machine’s position in the stand should not be inclined but
horizontally straight, exchange position 13 against 15. Do not use the
inclination support 14.
7

3.3 Setting the working height
–The working height is adjustable between 750 and 900 mm
(measured to the upper edge of the table plate).
–Undo screws 1on the stand braces.
–Adjust the table plate horizontally to the required working height.
To prevent tilting, pull the table plate out or push it in by the same
distance on both sides.
–Tighten both screws 1.
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4 Sewing drives
4. 1 Drive category, type and use
The following sewing drives are available:
Subclass Clutch motor DC-positioning drive
868-190020
868-290020
FIR 1147-F.752.3 *
FIR 1148-F.752.3
Efka DC1550/DA321G
Efka DC1550/DA321G**
868-190322
868-190341
868-290322
868-290341
868-390322
Efka DC1550/DA321G
Efka DC1550/DA321G**
* This clutch motor incorporates an electromagnetic brake that rapidly
stops the rotor when it runs on after the motor has been switched off.
This prevents the sewing machine from starting up unintentionally if
the pedal is operated shortly after switching off.
** For machines with the drive positioned under the table
4.2 Components of the drive sets
The desired drive is delivered as a “drive package” that, apart from
the drive, also includes the belt pulley, the V-belt, connection cables,
the pedal linkage, fixing material and diagrams.
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4.3 Fitting the sewing drive
–Attach the sewing drive 2 with its base 1 on the bottom side of the
table plate by screwing the three hexagonal screws (M8 x 15) with
washers into the nuts 8 of the table plate bottom.
4.4 Fitting the pedal
–Attach the pedal 4 to the stand brace 3.
–For ergonomic reasons align the pedal 4 as follows:
The center of the pedal must be approximately under the needle.
There are slots in the stand brace 3 to help align the pedal.
–Attach the ball pins to the lever 7 as required by the drive.
–Hook in the pedal linkage 5.
–Slightly undo screw 6.
–Adjust the height of the pedal linkage 5 as follows:
when released the pedal 4 should be inclined about 10°.
–Tighten screw 6.
10

4.5 Fitting the sewing-drive control for machines with Efka DC 1550 / DA 321G
–Fix the sewing-drive control 1with 4 screws underneath the table
plate 2.
–Fix the power supply cable of the sewing-drive control with the
traction relief clip 3underneath the table plate.
4.6 Fitting the set value initiator
–Screw angle 7under the table plate 8.
–Screw the set value initiator 2onto the angle 7.
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5 Assembling the machine head
The sewing machine heads of the class 868 can be fitted into the
stand horizontally straight as well as inclined.
Therefore the positions of the hinges on the machine head and the
fastening of the direct drive must be considered.
5.1 Fitting the hinges on the machine head
12
Position of the hinges for the
straight set-up of the machine head
Position of the hinges for the
inclined set-up of the machine

5.2 Fitting the direct drive
5.3 Tensioning the toothed belt of the direct drive
Loosen the screws 1in order to tighten the toothed belt. The belt
tension can be altered by shifting the motor with its support in the
oblong hole 2. Afterwards the screws 1must be tightened again.
The toothed belt tension is to be set so that when a load of 20N is put
on the belt center in the middle between the belt pulleys, the belt
shows a bow of 4+1 mm. The measure is be taken exactly in the middle
between the two belt pulleys.
When setting the belt tension with a measuring device the belt tension
should be about 150 Hz.
13
Position of the motor support for
the inclined set-up of the machine Position of the motor support for the straight set-up of the machine
21

5.4 Placing the sewing machine head on the stand
–If the sewing machine is equipped with motor on the table plate
bottom, place the machine head 1vertically into the table plate’s
cutout.
–If the machine is equipped with motor on the machine head,
incline the machine head 2in order to place it into the table plate’s
cutout.
–After placing the machine head immediately fix the retaining plate
that prevents the machine head from falling out when being tilted.
–The retaining plate 3is part of the accessories that come with the
machine head.
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5.5 Fitting and tensioning the V-belt
Only concerns machines with motor on the table plate bottom.
V-belt 2, V-belt pulley 1 and belt guard are part of the drive set
–Fix the V-belt pulley 1on the shaft of the sewing drive.
–Put the V-belt on the belt pulley 6on the machine head.
–Pass the V-belt 2down through the cutout of the table plate.
–Tilt the sewing machine head to the back.
–Place the V-belt 2on the V-belt pulley 1.
–Tilt the machine head back to the front.
–Loosen the screw 3on the socket 4of the sewing drive.
–Tension the V-belt 2by swivelling the sewing drive 5.
With the correct belt tension the V-belt 2bows by about 20 mm at
its mid-point under a load force of F =10 N (~1 kg).
–Tighten the screw 3.
–Set the belt inlet protection 9and the belt catch device 10 of the
belt guard 11. The V-belt 2must remain on the belt pulleys when
the sewing machine head is tilted backwards. See the motor
manufacturers’ operating instructions!
–Screw on the belt guard cover 11.
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5.6 Fitting the belt cover
–Remove the handwheel 1.
–When the machine’s motor is situated underneath the table plate
mount the belt cover 2on the machine head .
(The belt cover is part of the drive package)
–When the machine’s motor is situated on the sewing machine head
mount the belt cover 4and 5.
(The belt guard is part of the drive package)
–Mount the handwheel 1. Pay attention to the correct position:
The position of the needle in its upper dead center must
correspond to the value “0" on the handwheel’s graduated scale.
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