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
Part 2: Installation instructions –Class 838
1. Items delivered ............................................... 3
2. General and transport packaging ................................... 4
3. Assembling the stand
3.1 Assembling the stand components .................................... 4
3.2 Completing the table plate and mounting to the stand ........................ 5
3.3 Adjustingtheworkingheight........................................ 6
4. Assembling the sewing machine head
4.1 Integrating the sewing machine head into the stand.......................... 7
4.2 Assembling the protective belt cover on the sewing machine head................. 7
4.3 Pedal adjustment .............................................. 8
4.4 Assemblingthekneeleverandoilpumphose............................. 9
4.5 Assembling the connection cable, control panel, and diode illumination on the machine head . . 10
5. The special sewing machine’s electrical connections
5.1 Connecting the special sewing machine to the low voltage supply ................. 11
5.1.1 Connecting the sewing light transformer to the supply voltage ................... 12
5.2. Establishing equipotential bonding .................................... 13
5.3 Connecting the sewing machine head to the sewing drive ...................... 14
6. Adjusting the Efka positioning drive
6.1 Adjustingthepositioningdriveparameters............................... 15
6.1.1 Adjustingtheparameterswiththe“Auto-select”function ...................... 15
6.1.2 Class-838specificadjustmentstotheparametersoftheEfkadrive................ 15
6.1.3 SpecificparametervaluesfortheClass838.............................. 16
6.2 Adjustingthemachinepositioning .................................... 16
6.2.1 Definingthepositions ........................................... 16
6.2.2 Adjusting the machine positioning for the DC1550/DA321G drive ................. 16
6.2.2.1 General .................................................... 16
6.2.3 Checkingthesetpositions ........................................ 17
6.3 Masterreset ................................................. 17
7. Pneumatic connections.......................................... 18
8. Lubrication ................................................. 18
9. Sewing test ................................................. 19

For your notes:

1. Items delivered
It is possible to order either a complete sewing unit or only individual
components. Before setup, please check that all the required
components are present.
This description is valid for the special sewing machine whose
individual components are delivered directly and completely from
Dürkopp Adler AG. These directions describe the assembly and
installation of the special sewing machine.
Required components:
–Upper section (machine head) (1)
–Accessory pack (contains oil collector (2), reel stand (3), tools and
additional items)
–Parts set (contains direct drive (4), protective belt cover (5), and
additional parts)
Optional components:
–Stand (6)
–Operating panel (7)
–Compressed air maintenance unit (8)
–Pneumatic connection kit (9)
GB
3
1
2
3
4
5
7
8
6
9

2. General and transport packaging
Caution!
The special sewing machine may only be set up by trained personnel.
Transport packaging
If you have purchased 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.
3. Assembling the stand
3.1 Assembling the stand components
–Assemble the stand components according to the illustration.
Fasten the pedal (1) to the stand brace (3). Align the pedal after
you have assembled the complete machine.
–Turn the adjusting screw (2) to ensure a secure mount on the
stand. The stand must be resting with all four feet on the floor.
4
1
2
3

3.2 Completing the table plate and mounting to the stand
–Turn over the table plate (1).
–Screw on the cable channel (2).
–Screw on the setpoint director device (3).
–Screw on the cable clamp (4).
–Position the oil collector (5) in direction of arrow (6) so that the
edge of the oil collector is aligned with the table plate edge. Screw
on the oil collector.
–Screw on the drawer (7) together with its fixtures.
–Screw on the control unit (8) (the drill holes for the wood screws
are pre-drilled).
–Screw on the sewing light transformer (9) (optional equipment).
–Mount the electrical cable according to the instructions in
Chapter 5.
–Mount the table plate (1) to the stand using the wood screws
(B8x35). Drill the holes (10) for the wood screws. Turn the stand so
that it is positioned in its normal position.
–Put the reel stand (11) into the drilled hole in the table plate.
Fasten with nut and washer.
Mount and align the reel holder and unwinder holder.
These two holders must be positioned on top of each other.
–Put the support (12) in the drilled hole.
–Insert the lower hinge section (13) for the machine head into the
space on the table plate (1). Then screw it in.
–Insert the wedges (14) into the clearance space in the table plate
(for the rubber corners).
–Insert the rubber corners (15).
–Remove the plug (16) on the oil collector for the knee lever (17).
–Remove the knee lever (17) and guide through the opening, as
shown in the illustration.
GB
5
328
30
80
770
72
185
15
368 80
15
4
10 2 69 58 13 10
14
12
15
11
260
13
17
460
180
15
7
50
16
30

3.3 Adjusting the working height
–The stand height can be adjusted between 750 and 900 mm.
–Loosen the screws (1).
–Set the horizontal height of the table plate as needed. Check the
scale on the stand spar. The height of the stand should be
appropriate to the height and operating position of the operator.
–Tighten the screws (1).
Caution Danger of Injury!
Ergonomic-related, operator injuries can result if the stand height is
not adjusted to fit the operator.
6
1