Duerkopp Adler 869 User manual

869
Spezialnähmaschine
Betriebsanleitung
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
D
GB
Ausgabe / Edition: Änderungsindex Teile-Nr./Part.-No.:
03/2009 Rev. index: 00.0 Printed in Federal Republic of Germany 0791 869741

Alle Rechte vorbehalten.
Eigentum der Dürkopp Adler AG und urheberrechtlich geschützt. Jede, auch auszugsweise Wiederverwendung
dieser Inhalte ist ohne vorheriges schriftliches Einverständnis der Dürkopp Adler AG verboten.
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 - 2009

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 for Class 869
1. Scope of Delivery .............................................. 3
2. General and Transport Packaging ................................... 5
3. Assembling the Stand
3.1 MG55-3standassembly.......................................... 6
3.2 MG56-3standassembly.......................................... 7
3.3 CompletingthetableplatefortheMG55-3standwithFIRclutchmotor.............. 8
3.4 CompletingthetableplatefortheMG55-3standwithdirectdrive................. 9
3.5 CompletingthetableplatefortheMG56-3standwithFIRclutchmotor.............. 10
3.6 CompletingthetableplatefortheMG56-3standwithdirectdrive................. 11
3.7 Fasteningthetableplatetothestand................................... 12
3.7.1 MG55-3stand ................................................ 12
3.7.2 MG56-3stand ................................................ 13
3.8 Assembling the supports on the table plate with cut-out (MG 55-3) ................. 14
4. Setting the Working Height of the MG 55-3 stand .......................... 15
5. Sewing Drive
5.1 Drivetypeandapplication ......................................... 16
5.2 Components in the drive packages .................................... 16
6. Mounting the set-value initiator for the direct drive
6.1 MG55-3stand ................................................ 17
6.1.1 Aligning the pedal .............................................. 17
6.2 MG56-3stand ................................................ 18
6.2.1 Aligning the pedal .............................................. 18
7. Putting on the Machine Head....................................... 19
8. Putting on the V-belt and Tightening for the FIR Clutch Motor ................. 21
9. Mounting the Knee Lever ......................................... 22
10. Mounting the Direct Drive
10.1 Mounting the motor and putting on the V-belt .............................. 24
10.2 Connecting the Hall sensor ......................................... 24
10.3 Mounting the operating panel ....................................... 26
10.4 Mounting the sewing light (optional equipment)............................. 27
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Contents Page:
11. Electrical Connections
11.1 General..................................................... 28
11.2 Earthing .................................................... 28
11.2.1 Machine head ................................................. 28
11.2.2Kneeswitch.................................................. 29
11.3 Checking the mains supply voltage .................................... 30
11.4 Connecting the clutch motor (FIR) to the mains voltage........................ 30
11.4.1 Rotational direction of the clutch motor.................................. 31
11.4.2 Checking the rotational direction ..................................... 31
11.4.3 Changing the rotational direction ..................................... 31
11.4.4 Connecting the sewing light transformer (optional equipment).................... 32
11.5 Connecting the DC positioning drive to the mains voltage ...................... 33
11.5.1 Connecting the sewing machine head .................................. 33
11.5.2 Connecting the DA321G control unit ................................... 34
11.5.3 Checking the rotational direction of the DC positioning drive..................... 35
11.5.4Checkingthepositioning.......................................... 36
11.5.5Machine-specificparameters........................................ 36
11.5.6Masterreset.................................................. 37
11.5.7 Connecting the sewing light on the DA321G control unit ....................... 38
12. Pneumatic Connections .......................................... 39
13. Lubrication .................................................. 41
14. Sewing Test.................................................. 42

1. Scope of Delivery Sewing machine with MG 55-3 stand
GB
4
87
12
3
5
9
10

Sewing machine with MG 56-3 stand
4
8
7
11
1
10
2
12
3
13
14

GB
The items that are supplied depend on your order.
Before setup, please check that all the required components are
present.
The description is valid for the special sewing machine whose
individual components are delivered directly and completely from
Dürkopp Adler AG.
–1Machine head
Dürkopp Adler accessory with:
–2Reel stand
Protective cover (not shown)
Electric parts set, depending on your order, for:
Machines with direct drive
–3Protective belt cover
–11 DA control unit
–12 Operating panel
–13 Knee switch
Machines with clutch motor (FIR)
–3Protective belt cover
–5Main switch
–6Sewing drive
–9Knee lever
Optional equipment
–4Table plate (optional)
–7Stand (optional)
–8Pedal and rods (optional)
–10 Drawer (optional)
–14 Maintenance unit (optional)
2. General and Transport Packaging
CAUTION !
The special sewing machine may only be set up by trained personnel.
Transport packing
After purchasing a mounted sewing machine, you must remove the
following packaging:
–Safety straps and battens from the upper machine head, table and
stand.
–Safety blocks and straps from the sewing drive.
5

3. Assembling the Stand
There are two stand sets with different table plates available for the
669 class:
Stand set Version
MG 55-3 not separated, with or without cut-out
MG 56-3 separated, hinged
3.1 MG 55-3 stand assembly
–Assemble the stand according to the illustration.
–Fasten the pedal 2 to the stand brace 1.
–Mount the stand brace 1 to the stand.
–Align the pedal after you have assembled the complete machine.
–Screw on the holder for the oil can 3.
–Turn the adjusting screw 4 to ensure a secure mount on the stand.
–The stand must be resting with all four feet on the floor.
6
1
2
34

3.2 MG 56-3 stand assembly
–Assemble the stand according to the illustration.
–Fasten the pedal 2 to the stand brace 1.
–Mount the stand brace 1 to the stand.
–Turn the adjusting screws 4 to ensure a secure mount on the stand.
The stand must be resting with all six feet on the floor.
–Align the pedal after you have assembled the complete machine.
–Screw on the holder for the oil can 5.
–Assemble the rod 6 (only for FIR clutch motor).
7
GB
6
1
4
2
5
3
4

3.3 Completing the table plate for the MG 55-3 stand with FIR clutch motor
Top view of table plate
Marking for stand
–Turn over the table plate 4.
–Screw on the cable duct 1.
–Screwonmainswitch2.
–Screw on the power supply (optional equipment).
–Screw on the drawer 5 together with its fixtures.
–Screw on the sewing light transformer (optional equipment).
–Mount the clutch motor 7.
For this, screw the three hexagon bolts (M8 x 40) with washers into
the anchor nuts on the table plate.
The belt pulley 8 must point to the right when the table plate is
mounted.
–Mount the electrical cable according to the instructions in
chapter 12.
8
4
7
8
7
4
5(3,5x17) x2
6(4x20) x2
3(4x20) x2 2(5x25) x2
1(3,5x17) x2

GB
3.4 Completing the table plate for the MG 55-3 stand with direct drive
Top view of table plate
Marking for stand
–Turn over the table plate 5.
–Screw on the cable duct 1.
–Screw on the motor control 2.
–Screw on the power supply 3.
–Screw on the knee switch for the sewing-foot stroke.
(Only for subclasses 869-180322, 869-280322)
–Screw on the set value initiator 8 (refer to chapter 6.1).
–Screw on the drawer 6 together with its fixtures.
–Screw on the sewing light transformer 7 (optional equipment).
–Mount the electrical cable according to the instructions in
chapter 12.
9
2
5
4
6(3,5x17) 6x
7(4x20) 2x
1(3,5x17) 2x
3(4x20) 2x
8

3.5 Completing the table plate for the MG 56-3 stand with FIR clutch motor
Top view of table plate
Marking for
stand
–Turn over the table plate 8.
–Screw on the sewing light transformer 1 (optional equipment).
–Screw on the cable duct 3.
–Screw on the drawer 4 together with its fixtures.
–Screw on the main switch 5.
–Screw on the power supply 6 (optional equipment).
–Screw on flap trays 7 using two wood screws per tray.
–Mount the clutch motor 2.
For this, screw the three hexagon bolts (M8 x 40) with washers into
the anchor nuts on the table plate.
The belt pulley 9 must point to the left when the table plate is
mounted.
–Mount the electrical cable according to the instructions in
chapter 12.
10
7(5x25) 2x
2
2
7(5x25) 2x
9
4(3,5x17) 6x
1(4x20) 2x
3(3,5x17) 2x
6(4x20) 2x
8
5,5x25) 2x

GB
3.6 Completing the table plate for the MG 56-3 stand with direct drive
Topviewoftableplate
Marking for stand
–Turn over the table plate 5.
–Screw on the drawer 1 together with its fixtures.
–Screw on the motor control 2.
–Screw on the power supply 3.
–Screw on flap trays 7 using two wood screws per tray.
–Screw on the knee switch 4 for the sewing-foot stroke.
–Screw on the sewing light transformer 6 (optional equipment).
–Screw on the cable duct 8.
–Mount the electrical cable according to the instructions in
chapter 12.
11
8(3,5x17) 2x
42
5
7(5x25) 2x
7(5x25) 2x
6(4x20) 2x
1(3,5x17) 6x
3(4x20) 2x

3.7 Fastening the table plate to the stand
3.7.1 MG 55-3 stand
–Fasten the stand 4 to the table plate 1 using wood screws (6x30).
Pre-drill the holes for the wood screws.
Be sure to note the marking for the stand
(refer to chapters 3.3, 3.4).
–Turn the stand 4 so that it is in its normal position.
–Attach the rod 3 onto the pedal and motor.
–Put the reel stand 1 into the drilled hole in the table plate.
Fasten with nut and washer.
–Mount and align the reel holder and unwind holder.
These two holders must be positioned on top of each other.
12
1
4
2
3

3.7.2 MG 56-3 stand
–Fasten the table plate 2 to the stand 5 using wood screws (6x30).
Pre-drill the holes for the wood screws.
Be sure to note the marking for the stand (refer to chapters 3.5,
3.6).
–Fastenthetableplate8tothelatch7usingthreewoodscrews
(5x30).
–Attach the rod 6 onto the pedal and the actuating lever 4 (only for
FIR clutch motor).
–Attach the rod 3 onto the actuating lever 4 and motor.
–Put the reel stand 1 into the drilled hole in the table plate. Fasten
with nut and washer.
–Mount and align the reel holder and unwind holder.
These two holders must be positioned on top of each other.
13
GB
1
7
2
5
3
8
4
6

3.8 Assemble support on table plate with cut-out (MG 55-3)
In order to increase the stability of the right side of the table plate 1,
the plate is support by a junction bar.
–Fasten junction bar 2 to the stand using screw 3. Fasten bar to the
bottom of the table plate using two wood screws (5x30).
14
1
2
3

4. Setting the working height of the MG 55-3 stand
Caution: Risk of injury !
Ergonomic-related, operator injuries can result if the stand height
is not adjusted to fit the operator.
–The working height is adjustable between 750 mm and 900 mm
(measured to the upper edge of the table plate).
–Loosen the screws 1 in the stand spars.
–Adjust the table plate vertically to your required height.
Be sure to adjust (pull out and push in) both sides of the table plate
equally so that it does not tilt.
–Tighten screws 1.
15
GB
1

5. Sewing Drive
5. 1 Driver type and application
The following types of sewing drives are available:
Subclass Clutch motor DC-
positioning drive
869-180010 FIR 1147*.752.3 * Efka DC 1550/DA321G
869-280020 FIR 1148*.752.3
869-180122 Efka DC 1550/DA321G
869-280122
869-180322 Efka DC 1550/DA321G
869-280322
* This clutch motor has an electro-magnetic brake which quickly stops
the rotor after the motor has been turned off. This prevents the sewing
machine from running if the pedal is pressed shortly after the machine
has been turned off.
5.2 Components in the drive packages
Your requested drive is delivered in the form of a “drive package”. This
package includes not only the sewing drive but also belt pulley, V-belt,
connection cables, pedal rod, fastening materials and diagrams.
16