DURKOPP ADLER 867 - 10-2010 User manual

867
Spezialnähmaschine
Betriebsanleitung
Instruction manual
Instructions d’emploi
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
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GB
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Ausgabe / Edition: Änderungsindex Teile-Nr./Part.-No.:
10/2010 Rev. index: 07.0 Printed in Federal Republic of Germany 0791 867740

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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.
Tous droits réservés.
Propriété de la société Dürkopp Adler AG et protégé par la loi sur le droit d’auteur. Une copie ou reproduction
par quelque procédé que ce soit du contenu sans accord écrite de l’auteur est interdite.
Copyright © Dürkopp Adler AG - 2010

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 867 – Original Instructions
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 Assembling the stand components (Long arm) ........................... 9
3.4 Assemblingthetableplate ....................................... 9
3.5 Self-manufactureofthetabletop ................................... 9
3.6 Settingtheworkingheight........................................ 10
4. Sewing drives
4.1 Drivecategory,typeanduse...................................... 11
4.2 Fittingthesewingdrive.......................................... 12
4.3 Fittingthepedal.............................................. 12
4.4 Fittingthecontrolunitonmachineswithdirectdrive........................ 13
4.4.1 Fittingthesetvalueinitiator....................................... 14
4.4.2 Fittingthepedal.............................................. 15
4.5 Fitting the sewing-drive control for machines with direct drive (only 867-190142-M) .... 15
4.6 Fittingthesetvalueinitiator....................................... 15
4.7 Fittingthepedal.............................................. 16
5 Assembling the machine head
5.1 Fittingthemachinehead......................................... 17
5.2 Fittingtheoilsuctiontube ....................................... 17
5.3 FittingandtensioningtheV-belt.................................... 19
5.4 Attachingthekneelever......................................... 20
5.5 Fittingtheoperatingpanel........................................ 21
5.6 Fittingthesewinglamp(optionalequipment) ............................ 21
6 Electrical connection
6.1 General................................................... 23
6.2 Checking the mains voltage ....................................... 23
6.3 Connectingthesewingdrive ...................................... 23
6.3.1 Connectingtheclutchmotor...................................... 23
6.3.2 Connectingthecoupling-positioningactuator............................ 23
6.3.3 Connectingthedirect-currentpositioningactuator......................... 23
6.4 Earthing................................................... 24
6.5 Connectingthesewingdrivetothemains.............................. 25
6.6 Drive-control connection sockets ................................... 25
6.7 Fittingtheproximityswitch....................................... 26
6.8 Connectingthemachinehead ..................................... 26
6.9 Directionofrotationofsewingdrive.................................. 27
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Contents Page:
6.9.1 Checking the direction of rotation with the coupling-positioning
actuator (mounted under the table) .................................. 27
6.9.2 Changing the direction of rotation with the coupling-positioning
actuator (mounted under the table) .................................. 27
6.10 Connectingthesewinglighttransformer(optionalequipment).................. 28
6.10.1 Attachingandconnectingthesewinglighttransformer(optionalequipment)......... 28
6.10.2 Connection to the DA321G ....................................... 29
6.10.3 ConnectiontotheDACClassic..................................... 30
6.11 Connectingthedirectdrive....................................... 31
6.11.1 ConnectingtheHallsensor(optionalequipment).......................... 31
6.11.2 Connecting the DA321G control unit ................................. 33
6.11.3 ConnectingtheDACClassiccontrolunit............................... 33
6.12 Connectingthekneeswitch....................................... 34
6.13 Mounting the M-Control PCB ...................................... 35
6.14 SettingtheswitchesontheM-ControlPCB............................. 36
6.15 Settingmachine-specificparameters................................. 37
6.15.1 General................................................... 37
6.15.2 Autoselect ................................................. 37
6.15.3 Subclass 867-290342-100........................................ 37
7 Pneumatic connection
7.1 Pneumaticsewingfootlifting...................................... 40
8 Lubrication................................................. 41
9 Sewing test ................................................ 42

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9
3
8
7
6
5
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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 incl. oil sump
Dürkopp Adler accessory set with:
–2Reel stand
Protection cover (not represented)
–11 Oil tray
Set of electronic parts, depending on the order, for:
Machines with direct-current actuator
–4Sewing-drive control
–10 Operating panel
–12 Cover
Machines with positioning actuators
–Main switch
–Sewing-drive
–Synchronizer
–Belt guard
Optional equipment
–7 Stand (option)
–6 Pedal and pedal linkage (option)
–3 Table top (option)
–8 Drawer (option)
–Knee lever
–Pneumatic sewing foot lifting
2. General and transport packing
Caution:
The special sewing machine must be set up by trained specialist
personnel.
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!
DIRECT DRIVE
6
13
3
2
1
4
5
6
9
10
11
12
7
8
14
3,5x17 (x 6)
4,5x15 (x 4)
3,5x17 (x 2)
B8x35 (x 4)
3,9x15 (x 5)

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3. Assembling the stand
3.1 Assembling the stand components
–Assemble the individual stand components as shown in the
illustration.
–Adjust the set screws 8 to 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
(867-190020, 867-190040, 867-190122, 867-190142, 867-190145,
867-290020, 867-290040, 867-190322, 867-190342, 867-190445,
867-290322, 867-290342, 867-290445, 867-392342, 867-393342,
867-490322)
In order to have an optimal arrangement of the components, follow the
layout.
Stand Layout
MG55 400304 0791 867710
MG55 400314 0791 867711
–Screw the drawer 10 with its holders onto the left side underneath
the table plate.
–Screw the oil sump 7 under the table plate.
With sewing machine equipped with direct drive, all the three stops
should lie against the table opening.
With sewing machine equipped with the drive mounted under the table,
the stop 14 must have 9 mm distance from the table top 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.
–Put the cap 13 into the bore hole of the table plate.
–Place the hinge bottoms 12 for the machine head into the cutout
of the table plate 9 and tighten the screws.
–Insert the rubber corner 2.
–Attach the table plate 11 to the stand with woodscrews (B8 x 35)
(see sketch for position).
–Insert the yarn stand 1 in the 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.
9mm
oil sump table plate
DRIVE UNDER THE TABLE
7

8
MG58 400414
2
1
4
5
6
9
10
11
12
7
8
MG58 400404
3,9x15 (x 11)
3,5x17 (x 6)
3,5x17 (x 2)
B8x35 (x 4)
4,5x15 (x 6)

3.3 Assembling the stand components (Long arm)
–Assemble the individual stand components as shown in the
illustration.
–Adjust the set screws 8 to 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.
3.4 Assembling the table plate
(867-190040-70, 867-190342-70*, 867-290040-70, 867-392242-70*)
In order to have an optimal arrangement of the components,
please follow the layout.
Stand Layout
MG58 400414 0791 867716
MG58 400404 0791 867715
–Screw the drawer 10 with its holders onto the left side underneath
the table plate.
–Screw the oil sump 7 under the table plate.
–Put the cap 5 into the bore hole of the table plate.
–Screw the cable duct 4#under the table plate.
–Place the hinge bottoms 12 for the machine head into the cutout
of the table plate and tighten the screws.
–Insert the rubber corner 2.
–Attach the table plate 11 to the stand with woodscrews (see
sketch for position).
–Insert the reel stand 1 in the 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.
* MG58 400414 only available for the above-quoted underclass.
#Not applicable with sewing machines with direct drive.
3.5 Self-manufacture of the table top
If you manufacture the table top yourself, please take the
measurements from the illustrations on pages 43 and 44.
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3.6 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 1 on 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
867-190020 FIR 1147-F.752.3 *
867-190040 FIR 1148.552.3 *1 Efka DC1550/DA321G
867-290020
867-290040
867-392342
867-393342 Efka DC 1550/DA321G
867-394342
867-190142-M DAC Classic
867-190122
867-190142 Efka DC1550/DA321G
867-190322
867-190342
867-190125
867-190145
867-190425
867-190445
867-290445 Efka DC1550/DA321G
867-290122
867-290142
867-290322
867-290342
867-490322 Efka DC1550/DA321G
867-190020-70
867-190040-70
867-290020-70
867-290040-70 *1 Efka DC1550/DA321G
867-190122-70
867-190322-70
867-190342-70
867-290122-70
867-290322-70
867-290342-70
867-290342-100 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.
*1 only for machines with the drive under the table
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4.2 Fitting the sewing drive
–Attachthesewingdrive2withitsbase1ontheundersideofthe
table plate.
By screwing the three hexagonal screws (M8x35) with washers
into the table-plate nuts 8.
4.3 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.
–Screw the ball pins from the middle to the front hole in the lever 7.
–Attach pedal linkage 5.
–Slightly undo screw 6.
–Adjust the height of the pedal linkage 5 as follows:
when released the pedal 4 should be at an angle of about 10°.
–Tighten screw 6.
12
2
1
8
4
4
3
7
5
6

4.4 Fitting the sewing-drive control for machines with direct drive
–Fix the sewing-drive control 1 with 4 screws underneath the table
plate 8.
–Fix the power supply cable of the sewing-drive control with the
traction relief clip underneath the table plate.
4.5 Fitting the set value initiator
–Screw L-bracket 7 under the table plate 8.
–Screw the set value initiator 2 onto the L-bracket 7.
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13
1
8
2
5
7
6
3
4

4.6 Fitting the pedal
–Attach the pedal 5 to the stand brace 4.
–For ergonomic reasons align the pedal 5 as follows:
The center of the pedal must be approximately under the needle.
There are slots in the stand brace 4 to help align the pedal.
–Screw the ball pins from the middle to the front hole in the lever 7.
–Hinge the pedal linkage 3 with the ball sockets on the set value
initiator 2 and into the pedal 5.
–Loosen screw 6.
–Adjust the height of the pedal linkage 5 as follows:
when released the pedal 4 should be at an angle of about 10°.
–Tighten screw 6.
14
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7
6
3
4

4.5 Fitting the sewing-drive control for machines with direct drive (only 867-190142-M)
–Fix the sewing-drive control 1 with 4 screws underneath the table
plate 8.
–Fix the power supply cable of the sewing-drive control with the
traction relief clip underneath the table plate.
4.5 Fitting the set value initiator
–Screw L-bracket 7 under the table plate 8.
–Screw the set value initiator 2 onto the L-bracket 7.
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8
2
5
7
6
3
4

4.5.2 Fitting the pedal
–Attach the pedal 5 to the stand brace 4.
–For ergonomic reasons align the pedal 5 as follows:
The center of the pedal must be approximately under the needle.
There are slots in the stand brace 4 to help align the pedal.
–Screw the ball pins from the middle to the front hole in the lever 7.
–Hinge the pedal linkage 3 with the ball sockets on the set value
initiator 2 and into the pedal 5.
–Loosen screw 6.
–Adjust the height of the pedal linkage 5 as follows:
when released the pedal 4 should be at an angle of about 10°.
–Tighten screw 6.
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2
5
6
3
4