DURKOPP ADLER 838 User manual

838
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
Ausgabe / Edition: Änderungsindex Teile-Nr./Part.-No.:
10/2008 Rev. index: 00.0 Printed in Federal Republic of Germany 0791 838740
D
GB

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 - 2008

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.

GB
Contents Page:
Preface and general safety instructions
Part 1: Operating instructions - Class 838
(Edition 10/2008)
1. Product description ............................................ 5
2. Designated use ............................................... 5
3. Subclasses and sewing equipment
3.1 Subclasses.................................................. 6
3.2 Sewing equipment ............................................. 6
4. Optional equipment ............................................ 7
5. Technical data
5.1 Class-specifictechnicaldata ....................................... 8
5.2 Subclass-specifictechnicaldata..................................... 8
6. Operations
6.1 Threading the needle thread ....................................... 9
6.2 Winding on the hook thread ........................................ 10
6.3 Changing the hook thread bobbin .................................... 10
6.4 Adjustingthethreadtension ....................................... 11
6.4.1 Adjusting the hook thread tension .................................... 11
6.4.2 Adjusting the needle thread tension ................................... 12
6.5 Switching the thread tensioners on/off ................................. 13
6.5.1 The functioning of the main thread tension and the supplementary thread tension
inrelationtothesewingfootlift...................................... 14
6.6 Adjusting the thread regulator ...................................... 14
6.7 Changing the needle for single-needle machines ........................... 15
6.8 Changing the needle for double-needle machines .......................... 16
6.9 Liftingandfoldingthetoproller...................................... 17
6.10 Sewingfootpressure............................................ 18
6.11 Sewinginreverse(back-tacking) .................................... 19
6.12 Adjusting the stitch length ......................................... 20
6.13 Engaging the safety clutch for hook blockages............................. 21
6.14 Operatingthemachinewiththepositioningdrive ........................... 23
6.14.1 With the pedal ................................................ 23
6.14.2 With the buttons (key panel) ....................................... 24
7. Positioning drive on the Efka DC 1550/DA321G .......................... 25
8. Sewing on a machine with positioning drive
8.1 Automaticmachinefunctions ....................................... 26
8.2 Example - operating the machine while sewing ............................ 27

Contents Page:
9. Maintenance
9.1 Cleaning and testing ............................................ 28
9.2 Lubrication .................................................. 30

1. Product description
The Dürkopp Adler 838 is a special all-purpose sewing machine.
·It is a post-bed double-lockstitch machine.
·It has a bottom drop (feed) mechanism and a drive-powered top
roller.
·There are two setting wheels (knobs) which allow the selection of
two stitch lengths. There is also a pneumatically-controlled device
with a button for toggling between the two stitch lengths during
sewing.
·Depending on if the subclass is a single-needle or double-needle
sewing machine, the following automatic functions are featured: an
electro-magnetic thread trimmer, pneumatically-controlled
bartacking, a sewing foot lift, and a switchable upper thread
tensioner.
·The machine is equipped with a large double-sectioned vertical
hook.
·The maximum lift for the sewing foot is 12 mm.
·There is a safety clutch to avoid displacing or damaging the hook if
the thread gets jammed in the shuttle track.
·Depending on the width of the needle, swappable throat plate
inserts with corresponding stitching holes can be swapped out at
the throat plate.
·The machine features automatic wick lubrication and a viewing
window in the arm for watching the machine and hook lubrication.
Some of the oil is lost during the hook lubrication. The remaining oil
is redirected by the pump back to the central reservoir.
·Integrated bobbin winder.
2. Designated use
The 838 machines are suitable for use in producing shoes, decorative
ornamental work, and upholstery. The typical sewing material is leather
(either natural or synthetic). The sewing machine can also be used for
sewing shoe textiles.
The setup of the machine depends on the material to be sewed and
whether it is heavy or extra heavy.
Generally only dry material may be sewn with this sewing unit. The
material may be no thicker than 7 mm when compressed by the
lowered top roller.
The sewing material must not contain any hard objects since the
sewing machine is not equipped with any form of eye protection.
This sewing machine may be set up and operated only in dry,
well-maintained premises. If the sewing machine is used in other
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.
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GB

3. Subclasses and sewing equipment
3.1 Subclasses
Class and
Subclass
Number of
needles
Stitch length Machine-
control
Hook Trimming and
seam tacking
one needle, hook to right of needle
two needles
up to 8 mm autom. foot lift pneumatic seam tacking large two-section with thread trimming, autom. seam tacking
0838 170522 X X X X X
0838 270522 X X X X X
3.2 Sewing equipment
0,01
mm 0,01 mm - - mm 1/min 1/min mm mm mm dB (A)
838-E1 1 heavy 120-160 120 25-10 20 8 2000 1600 35 1,5 -
838-E2 1 extra
heavy 180-230 180 10-8 10 8 1600 1600 35 1,5 -
838-E3/1,6 2 heavy 120-180 180 25-10 10 8 2000 1600 35 1,5 1,6
838-E4/2,0 2 heavy 120-180 180 25-10 10 8 2000 1600 35 1,5 2,0
838-E5/2,4 2 heavy 120-180 180 25-10 10 8 2000 1600 35 1,5 2,4
838-E6/3,2 2 heavy 120-180 180 25-10 10 8 2000 1600 35 1,5 3,2
* You must reduce the sewing speed significantly when sewing through very thick materials.
** Noise level of the special sewing machine at the work place, as measured for the maximum stitch length and
the maximum sewing speed in compliance with DIN 45635-48-A-1-KL2.
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Sewing equipment Class and sub-class Number of neeles Sewing type Range Needle width:
Nm
Standard Range
Label number of
Standard polyester thread max. stitch length Max.
Sewing speed
Standard * Top roller diameter Gearing gap for the feed dog Seam clearance gap Noise intensity level of machine **
0838 1705220838 270522

4. Optional equipment
Order No. Optional equipment
0888 220334 Top roller Æ25 mm, knurled
0888 220344 Top roller Æ25 mm, smooth
0888 220354 Top roller Æ25 mm, rubber coating
0888 220364 Top roller Æ35 mm, knurled (thoroughly)
0888 220374 Top roller Æ35 mm, smooth
0888 220384 Top roller Æ35 mm, rubber coating
0888 220394 Top roller Æ45 mm, width: 3.8 mm
0888 220404 Top roller Æ45 mm, width: 2.0 mm
9880 888100 Sewing lamp LED
MG55-3 400324 Stand set for machines powered by drive belts
(contains frame, pedal, drawer and table top 1060 x 50 mm)
0700 088804 Table top for drive belt
N800 080030 Edge-guide, swivelling
N800 080004 Edge-guide with roller, swivelling
9780 000108 Compressed air unit
0797 003031 Complete compressed air hose
9805 791113 USB memory key for transferring data with the Efka DA321G control unit
0867 490010 Holder bracket for the Efka V810 or V820 control panel
0688 130384 Knee level for mechanical foot lift
9880 002001 Knee switch
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GB

5. Technical data
5.1 Class-specific technical data
Type of stitch Lockstitch 301
Needle system 134LR, 134 KKLR, 134, 134 D
Foot lift with hand lever 6 mm
Foot lift with knee lever or automatic 12 mm
Remaining thread length after thread trimming max. 15 mm
Clearance height of machine head 300 mm
Clearance width of machine head 280 mm
Dimensions of footprint of the machine bed plate 178 x 518 mm
Dimensions of footprint of table plate 1060 x 500 mm
Min. height of the table plate 740 mm
Max. height of the table plate 900 mm
Height of machine max. 1630 mm
Max. (short-term) power consumption 0.8 kW
Compressed air feed 6 bar
5.2 Subclass-specific technical data
Class and
subclass
Number of needles Column length Column heigth in sewing direction Column width perpendicular to sewing direction Weight of machine head Weight of frame Weight of Efka DC1550 motor
mm mm mm kg kg kg
0838 170522 1 170 52 59 55 30 10
0838 270522 2 170 52 59 56 30 10
More detail about the technical data are given in the chapter 3.2.
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