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.

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Contents Page:
Preface and General Safety Instructions
Part 1: Operating Instructions Class 869
(Edition 03/2009)
1. Product Description ............................................ 4
2. Designated Use ............................................... 4
3. Subclasses .................................................. 5
4. Optional Equipment ............................................ 6
5. Technical data
5.1 Technicaldatasubclasses ......................................... 8
6. Operation
6.1 Threading the needle thread ........................................ 10
6.2 Adjusting the needle-thread tension ................................... 11
6.2.1 Function of the main thread tension and the supplementary thread tension in relation to the
sewing foot lifting for subclass 869- ... .................................. 12
6.2.2 Function of supplementary thread tension in relation to the sewing foot lifting and the
Speedomat for subclass 869- ... ..................................... 13
6.3 Opening the thread tension ......................................... 13
6.4 Turning the supplementary thread tension on and off for Subclasses
869-180020, 869-280020, 869-180122 and 869-280122 ....................... 14
6.5 Adjusting the thread regulator ....................................... 15
6.6 Winding on the hook thread......................................... 16
6.7 Changing the hook-thread bobbin ..................................... 17
6.8 Setting the hook thread tension ...................................... 18
6.9 Inserting and changing the needle with single-needle machines .................. 19
6.10 Inserting and changing the needle with double-needle machines .................. 20
6.11 Liftingthesewingfoot............................................ 21
6.12 Lockingthesewingfeetinliftedposition................................. 22
6.13 Sewingfootpressure ............................................ 22
6.14 Sewing-footstroke.............................................. 23
6.15 Setting the stitch length ........................................... 25
6.16 Keypadonthemachinearm........................................ 26
7. Sewing
7.1 SewingwithmachinesusingtheFIRclutchpositioningdrive .................... 27
7.2 Sewing with machines using the Efka DC1550/DA321G positioning drive ............ 28

Contents Page:
8. Tilting Back the Machine Head ..................................... 31
9. Folding Down the Table Top with the MG 56-2 Stand ....................... 32
10. Maintenance
10.1 Cleaning and Checking ........................................... 33
10.2 Oil Lubrication................................................. 35
4

1. Product Description
The DÜRKOPP ADLER 869 is a single-needle double lockstitch
free-arm sewing machine with a lower feed, a needle feed and an
alternating foot-upper feed.
Depending on the subclass it comes as single or double needle
machine, with or without electropneumatic driven thread trimmer.
·The machines are equipped with a large horizontal hook.
·With a maximum of 20 mm fabric clearance when sewing feet are
lifted.
·The residual thread length after thread trimming is about 15 mm.
·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.
·All Subclasses, excluding those classes without thread trimmer
device, are equipped with a keypad (6 keys). An additional key,
within reach of the seamstress, can optionally also be assigned
one of the six different functions.
·Integrated bobbin winder
2. Designated use
The class 869 is a sewing machine head designed for sewing light to
medium-heavy material. Such material is generally made of textile
fibres, 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 sewing machine
head. 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 eye-protection device is currently
available.
The seam is generally produced with textile-fibre sewing thread of
gauge up to 10/3 NeB (cotton), 10/3 Nm (synthetic) or 10/4 Nm
(covering yarn).
Before using any other thread the possible dangers arising must be
assessed and appropriate safety measures taken if necessary.
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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 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
869-180020 Single-needle double lockstitch free-arm sewing
machine with lower feed, needle feed and alternating
foot upper feed.
869-180122 Single-needle double lockstitch free-arm sewing
machine with lower feed, needle feed and alternating
foot upper feed, electro-pneumatic thread trimmer,
electro-pneumatic seam bartacking and sewing foot
lifting. With large hook.
869-180322 Single-needle double lockstitch free-arm sewing
machine with lower feed, needle feed and alternating
foot upper feed, electro-pneumatic rapid stroke
adjustment, electro-pneumatic thread trimmer,
connectable thread tension, electro-pneumatic seam
bartacking, electro-pneumatic second stitch length
and sewing foot lifting. With large hook and
integrated sewing light.
869-280020 Double-needle double lockstitch free-arm sewing
machine with lower feed, needle feed and alternating
foot upper feed.
869-280122 Double-needle double lockstitch free-arm sewing
machine with lower feed, needle feed and alternating
foot upper feed, electro-pneumatic thread trimmer,
electro-pneumatic seam bartacking and sewing foot
lifting. With large hook.
869-280322 Double-needle double lockstitch free-arm sewing
machine with lower feed, needle feed and alternating
foot upper feed, electro-pneumatic rapid stroke
adjustment, electro-pneumatic thread trimmer,
connectable thread tension, electro-pneumatic seam
bartacking, electro-pneumatic second stitch length
and sewing foot lifting. With large hook and
integrated sewing light.
6

4. Optional Equipment
The following optional equipment is available for the 869.
Order No. Optional equipment Subclasses
869-180020 869-180122 869-180322 869-280020 869-280122 869-180322
9780 000108 WE-8 maintenance unit for pneumatic x x x x x x
optional equipment
0797 003031 Pneumatic connection package x x x x x x
For connection of stand with maintenance unit.
0867 490010 Operating panel angle bracket x o o x o o
9822 510001 Halogen sewing light for sewing machine head x x x x x x
9880 867100 Sewing light add-on kit x x x x x x
0798 500088 Sewing light transformer x x x x x x
9880 867103 Sewing light LED x x x x x x
9880 867102 Integrated sewing light x x o x x o
9850 001089 Power supply complete for integrated sewing light x x o x x o
and sewing light LED
9850 867001 PCB for oil monitoring x o x o
0867 590014 Electro-pneumatic needle cooler from the top x x
0867 590344 Mech. sewing foot lifting, with pedal x x
0867 590354 Pneumatic sewing foot lifting; for clutch pos. drive x x
0867 590364 Pneumatic sewing foot lifting; for DC 1550 x x
0867 590464 Manual seam tacking o x o o x o
N800 080004 Edge guide, swivelling (like Del Veccia) x x x x x x
9805 791113 USB memory key x x x x x x
for data transfer with the
Efka control unit DA321G.
Stands
MG55 400384 Stand set table top 1200x550 without cut-out x x x x x x
MG55 400394 Stand set table top 1200x550 with cut-out x x x x x x
MG56 400064 Stand set table top 1250x600 x x
divided, foldable, for clutch motors
MG56 400074 Stand set table top 1250x600 x x x x x x
divided, foldable, for DC 1550
o = Standard equipment
x = Optional equipment
GB
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Further available documents concerning the class 869:
0791 869801 Parts List
0791 869641 Service Instructions
5. Technical data
Noise: Workplace-related emission value in accordance with DIN 45635-48-A-1-KL2
869-180020 LC = _dB (A)
Stitch length: _ mm Sewing-foot stroke: __ mm Speed: ___ min-1
Material:
869-180122 LC = _dB (A)
Stitch length: _ mm Sewing-foot stroke: __ mm Speed: ___ min-1
Material:
869-180322 LC = _dB (A)
Stitch length: _ mm Sewing-foot stroke: __ mm Speed: ___ min-1
Material:
869-280020 LC = _dB (A)
Stitch length: _ mm Sewing-foot stroke: __ mm Speed: ___ min-1
Material:
869-280122 LC = _dB (A)
Stitch length: _ mm Sewing-foot stroke: __ mm Speed: ___ min-1
Material:
869-280322 LC = _dB (A)
Stitch length: _ mm Sewing-foot stroke: __ mm Speed: ___ min-1
Material:
8

GB
9
5.1 Technical data subclasses
Subclass
869-180020 869-180122 869-180322 869-280020 869-280122 869-180322
Type of stitch Lockstitch 301
Hook type vertical, large
Number of needles 1 2
Needle system 134-35
Needle size max. (depending on E-No.) [Nm] 180
Max. thread thickness
Needle thread [Nm] 80/3 - 10/3
Hook thread [Nm] 100/3 - 10/3
Stitch length [mm]
Forwards 9
Reverse 9
Max. speed [min-1] 2800
Speed factory setting [min-1] 2800
Max. sewing-foot stroke [mm] 9
Height of the lifted sewing feet max. [mm] 20
Operating pressure [bar] 6
Air consumption per working cycle [NL] 0,7
Dimensions (L x B x H) [mm] 600/ 230/ 470 650/ 230/ 470
(with the Efka DC 1550 mounted) (600/ 300/ 470) (650/ 300/ 470)
Weight [kg] 52 53
(with the Efka DC 1550 mounted) (56) (57)
Rated voltage [V/Hz] Depending on the drive
package
Rated voltage (factory setting) [V/Hz] Depending on the drive
package
Rated power [kVA] Depending on the drive
package

Threading scheme single-needle machine
Threading scheme double-needle machine
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1
2
3
4
5
11
10
9
8
7
6
12
13
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22
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6. Operation
6.1 Threading the needle thread
Caution: Risk of injury!
Turn off the main switch!
The needle thread may only be threaded with the sewing machine
switched off.
Threading in the needle thread with single-needle machines
–Put the thread reel on the thread stand and lead the needle thread
through the unwinder arm. The unwinder arm must be in vertical position
above the thread reels.
–Thread in the thread through threading guide 1 and 2.
–Pass the thread clockwise around the pre-tensioner wheel 3.
–Pass the thread counter-clockwise around the supplementary tensioner
wheel 4.
–Pass the thread clockwise around the around the main tensioner
wheel 5.
–Pull the thread underneath the thread take-up spring 8 and pass it
through the thread regulator 10 to the thread lever 11.
–Pass the thread through the thread lever 11 and the threading guides 9, 7
and 6 on the needle bar.
–Thread the thread into the needle eye.
Threading in the needle thread with double-needle machines
–Put the thread reels on the thread stand and lead the needle thread and
hook thread through the unwinder arm. The unwinder arm must be in
vertical position above the thread reels.
Thread for the left needle (as with single-needle machines)
–Thread in the thread through threading guide 1 and 2.
–Pass the thread clockwise around the pre-tensioner wheel 3.
–Pass the thread counter-clockwise around the supplementary tensioner
wheel 4.
–Pass the thread clockwise around the around the main tensioner
wheel 5.
–Pull the thread underneath the thread take-up spring 8 and pass it
through the thread regulator 10 to the thread lever 11.
–Pass the thread through the thread lever 11 and the threading guides 9, 7
and 6 on the needle bar.
–Thread the thread into the needle eye.
Thread for the right needle
–Thread in the thread through threading guide 12 and 13.
–Pass the thread clockwise around the pre-tensioner wheel 14.
–Pass the thread counter-clockwise around the supplementary tensioner
wheel 15.
–Pass the thread clockwise around the around the main tensioner
wheel 16.
–Pull the thread underneath the thread take-up spring 19 and pass it
through the thread regulator 21 to the thread lever 22.
–Pass the thread through the thread lever 22 and the threading guides 20,
18 and 17 on the needle bar.
–Thread the thread into the needle eye of the right needle.
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6.2 Adjusting the needle-thread tension
Pre-tension
When the main tensioner 2 and supplementary tensioner 3 are open,
the needle thread must be under slight residual tension. This residual
tension is produced by the pre-tensioner 1.
The pre-tensioner 1 simultaneously affects the length of the end of the
severed needle thread (the starting thread for the next seam).
–Basic setting:
Turn knurled nut 4 until its front is flush with the bolt 5.
–To shorten the starting thread:
Turn knurled nut 4 clockwise.
–To lengthen the starting thread:
Turn knurled nut 4 counter-clockwise.
Main tension
The main tensioner 2 should be set to the minimum possible tension.
The interlacing of the threads must be in the center of the material.
With thin material excessive thread tension can cause unwanted
gathering and thread breakage.
–Adjust the main tensioner 2 so that the stitches are uniform.
To increase tension - Turn the knurled nut clockwise
To decrease tension - Turn the knurled nut counter-clockwise
Supplementary tension
The supplementary tensioner 3 is used for rapid change in
needle-thread tension during operation (e.g. with thickened seams).
–Set the supplementary tensioner 3 lower than the main tensioner 2.
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Fig. A Correct thread interlacing in the center of the
material
Fig. B Needle-thread tension too weak
or
Hook-thread tension too strong
Fig. C Needle-thread tension too strong
or
Hook-thread tension too weak
6.2.1 Function of the main thread tension and the supplementary thread tension in relation to the sewing
foot lifting for subclass 869- ...
The thread supplementary tension can, at any time, be switched on or
off by actuating key 1 (see chapter 6.15) of the key pad. The parameter
F-299 must be set on “1" for this to work.
Sewing foot lifting Sewing foot lifting
during seam after
thread trimming
Parameter Thread- Thread- Thread- Thread-
Setting main- supplement.- main supplement.
tension tension tension tension
F-196=0 0 0 0 0
F-196=1 1 1 0 0
F-196=2 0 0 1 1
F-196=3 1 1 1 1
1 = Thread tension opened mechanically
0 = Thread tension closed mechanically
·If the supplementary thread tensioner is open, this condition will be
maintained when lifting the sewing foot.
·When switching the machine off, the last setting of the
supplementary thread tensioner will be maintained through the
mains connection.
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6.2.2 Function of supplementary thread tension in relation to the sewing foot lifting and the Speedomat
for subclass 869- ... The thread supplementary tension can, at any time, be switched on or
off by actuating key 1 (see chapter 6.14) of the key pad. The parameter
F-255 must be set on “7" for this to work.
Parameter Stroke adjustment max. Stroke adjustments
Setting via knee switch setting wheel
Reaching of the HP-speed
of parameter F-117
(Speedomat)
F-197 = 0 1 1
F-197 = 1 0 1
F-197 = 2 1 (*) 0
F-197 = 3 0 0
(*) If the stroke adjustment (max.) is switched on via the knee switch
and the HP-speed (from parameter F-117) is reached through the
“Speedomat”, then the supplementary thread tensioner will be switched
on automatically.
0 = Supplementary thread tension closed mechanically
1 = Supplementary thread tension opened mechanically
·If the supplementary thread tensioner is closed, this condition will
be maintained when adjusting the stroke.
·When switching the machine off, the last setting of the
supplementary thread tensioner will be maintained through the
mains connection.
Basic setting of the control unit for the automatic stepped reduction of
the speed (Speedomat) through the setting wheel for the height of the
alternating feed stroke
Parameter 188
Step 01-21 Entire Speedomat range
Step 01-10 max. allowed speed, Parameter
F-111 = 3000 min-1
Step 11-18 Linear stepwise reduction of the max. speed
(Speedomat)
Step 19-21 max. allowed speed, Parameter
F-117 = 1.800 min-1
6.3 Opening the thread tension
Subclasses
869-180020, 869-280020
When lifting the sewing feet with the knee lever, the main and
supplementary tensioners are automatically opened.
Subclasses
869-180122, 869-180322, 869-280122, 869-280322
The needle thread tension is automatically opened when trimming the
thread.
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6.4 Turning the supplementary thread tension on and off for subclasses
869-180020, 869-280020, 869-180122 and 869-280122
The supplementary tension is being switched on and off with lever 1.
Switching on
–Push the handle 2 of lever 1 to the left.
Switching off
–Push the handle 2 of lever 1 to the right.
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21

6.5 Adjusting the thread regulator
Caution: Risk of injury!
Turn off the main switch.
The thread regulator may only be adjusted with the sewing machine
switched off.
The thread regulator 1 controls the quantity of needle thread required
for stitch formation.
The thread regulator must be precisely adjusted for an optimum result.
At the correct setting the needle thread loop must be able slide with
low tension over the thickest point of the hook.
–Loosen the screw 2.
–Change the position of the thread regulator 1.
Thread regulator to the left = more thread
Thread regulator to the right = less thread
–Fasten the screw 2.
Adjustment information:
If the maximum quantity of thread is required, the thread take-up
spring 3 must be pulled upwards about 0.5 mm from its lower end
position. This is the case when the needle-thread loop passes the
maximum hook diameter.
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32 1

6.6 Winding on the hook thread
–Put the thread reel on the thread stand and lead the needle thread
through the unwinder arm.
–Pull the thread through the thread guide 3, the tensioner 5 and the thread
guide 3.
–Clamp the thread behind the blade 6 and tear it off.
–Fit the bobbin 1 on the bobbin winder.
There is no need to wind the thread around the bobbin by hand.
–Press the bobbin-winder lever 2 into the bobbin.
–Sewing.
The bobbin-winder lever terminates the process as soon as the bobbin is
full.
The bobbin winder always stops in such a position that the blade 6 is in
the insertion position
(see right-hand illustration)
–Remove the full bobbin 1, clamp the thread behind the blade 6 and tear it
off.
–Fit empty bobbin on the bobbin winder for the next winding process and
press the bobbin-winder lever 2 into the bobbin.
Attention: Danger of breakage!
If the thread is not to be wound on during sewing, it is essential for the
sewing foot to be locked in the raised position and the sewing-foot
stroke set to the smallest value.
GB
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543 21 26

6.7 Changing the hook-thread bobbin
Caution: Risk of injury!
Turn off the main switch.
The hook-thread bobbin may only be changed with the machine
switched off.
Remove the empty bobbin
–Slide the cover 1 sideways, raise up the flap 7 and remove the empty
bobbin 2.
Insert a full bobbin
–Insert the bobbin 2 so that it moves in the opposite direction of the hook
when unwinding.
–Pass the hook thread through the slit 3 and underneath the spring 4.
–Pull the hook thread through the slit 6 and continue pulling until it stands
out about 3 cm.
–Close the flap 7 and pull the hook thread through the thread guide 5 of
the flap.
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3