DURKOPP ADLER 867 Operating instructions

867
Spezialnähmaschine
Serviceanleitung
Service Instructions
Instructions de service
Istruzioni per il servizio
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.:
02/2010 Rev. index: 03.0 Printed in Federal Republic of Germany 0791 867641
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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.

GB
Contents Page:
Service instructions class 867
(Edition 02.2010)
1. General notes
1.1 Gauges..................................................... 3
1.2 Descriptionofthelockingpositions.................................... 4
1.3 Graduation on the handwheel ....................................... 5
2. Sewing machine
2.1 Positionofthearmshaftcrankonthearmshaft............................ 6
2.2 Upper and lower toothed belt wheel / toothed belt ........................... 7
2.2.1 Position of the upper toothed belt wheel ................................. 7
2.2.2 Position of the lower toothed belt wheel ................................. 8
2.3 Bottom feed and stitch regulator gear .................................. 9
2.3.1 Basicsettingofstitchadjustment..................................... 9
2.3.2 Adjust the 2nd stitch length......................................... 11
2.3.3 Positionofthefeeddoginthethroatplatecutout........................... 12
2.3.4 Feeding motion of the feed dog ...................................... 14
2.3.5 Liftingmotionofthefeeddog ....................................... 15
2.3.6 Feeddogheight ............................................... 16
2.3.7 Balanceweight................................................ 17
2.4 Transmissionlever.............................................. 18
2.5 Needle bar linkage .............................................. 19
2.5.1 Align the needle bar linkage laterally ................................... 19
2.5.2 Needle penetration in feeding direction ................................. 20
2.6 Hook, looping stroke and needle bar height ............................... 21
2.6.1 Looping stroke ................................................ 21
2.6.2 Needle bar height .............................................. 22
2.6.3 Distance between hook and needle.................................... 23
2.6.4 Needle guard ................................................. 24
2.7 Bobbin case opening ............................................ 25
2.7.1 General .................................................... 25
2.7.2 Setting of the bobbin case opening .................................... 25
2.7.3 Timing of opening .............................................. 27
2.8 Feeding foot and presser foot ....................................... 28
2.8.1 Feeding foot and presser foot stroke ................................... 28
2.8.2 Stroke motion of the feeding foot ..................................... 29
2.8.3 Sewingfootpressure ............................................ 30
2.9 Stitch length limitation ............................................ 31
2.10 Stitch equality of the forward and backward stitch ........................... 32
2.11 Sewingfootlifting .............................................. 33
2.11.1 Mechanical sewing foot lift ......................................... 33
2.11.2 Height of the sewing feet arrested with hand lever........................... 34
2.11.3 Heightoftheliftedsewingfeet....................................... 35

Index Page:
2.12 Thread-guiding parts ............................................ 36
2.12.1 Thread regulator ............................................... 36
2.12.2Threadtake-upspring............................................ 37
2.13 Bobbin winder................................................. 38
2.14 Threadcutter................................................. 40
2.14.1 General .................................................... 40
2.14.2Threadpullingknife............................................. 42
2.14.3 Counter-knife and lower thread clamp .................................. 44
2.14.4Cuttingposition................................................ 46
2.15 Shortthreadcutter.............................................. 48
2.15.1 General .................................................... 48
2.15.2 Locking latch for the thread-pulling knife ................................ 49
2.15.3Threadpullingknife............................................. 50
2.15.4 Counter knife ................................................. 52
2.16 Potentiometerinthearm.......................................... 54
2.16.1 Basic setting without control panel .................................... 54
2.16.2 Basic setting with the control panel V810 or V820 ........................... 55
2.16.3Checkthepotentiometeradjustment................................... 56
2.17 Connections PCB .............................................. 57
2.18 Machines with moving binder ....................................... 58
2.19 Machineswithverticaltrimmer ...................................... 59
3. Oil lubrication
3.1 Hooklubrication ............................................... 63
3.2 Maintenance ................................................. 64

GB
1. General notes
The present service instructions describe the adjustment of the special
sewing machine 867.
ATTENTION !
The operations described in the service instructions must only be
executed by qualified staff or correspondingly instructed persons
respectively!
Caution: Danger of injury !
In case of repair, alteration or maintenance work turn off the main
switch and disconnect the machine from the pneumatic supply system.
Carry out adjusting operations and functional tests of the running
machine only under observation of all safety measures and with
utmost caution.
The present service instructions describes the adjustment of the
sewing machine in an appropriate sequence. Please observe in this
connection that various setting positions are interdependent. Therefore
it is absolutely necessary to do the adjustment following the described
order.
For all setting operations of parts involved in the stitch formation a new
needle without damage has to be inserted.
Machine covers having to be screwed off and on again for checking
and adjusting operations are not mentioned in the text.
Note:
Some of the shafts of the special sewing machine 867 are provided
with flat spots. This facilitates the adjustment considerably.
In case of all adjustments on flat spots the first screw in rotation
direction is put on such a flat spot.
1.1 Gauges
The locking pin 1required for adjusting the machine belongs to the
serial equipment of the machine. It is in the accessories and can be put
at the bottom side of the oil pan.
3
1

1.2 Description of the locking positions
With the locking pin 1and the arresting grooves 2and 3in the arm
shaft crank 4the sewing machine can be arrested in two adjusting
positions.
Position I = Locking pin Ø 5 mm for large groove
= Looping stroke, needle bar height
Position II = Locking pin Ø 3 mm for small groove
= Needle bar at its upper dead center, graduation on the
handwheel
4
2
4
1
3

1.3 Graduation on the handwheel
The handwheel 2has a graduation printed on it.
Certain settings are carried out according to the position of the
handwheel.
–Turn the handwheel until the degree mark mentioned in this manual
points to the index 3.
–Carry out the described adjustment.
Setting the handwheel
–Setting the handwheel to the degree mark 50°
–Loosen the threaded pin for the handwheel through opening 1.
–Set the handwheel to 0°
–Arrest the machine in position II with the locking pin Ø 3 mm
–Loosen the threaded pin for the handwheel through opening 1.
–Turn the handwheel 2so that the degree mark 0° points to the
middle of the index 3.
–Tighten the threaded pin for the handwheel through opening 1.
–Set the handwheel to 50° and tighten the threaded pin for the
handwheel.
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1
2
3

2. Sewing machine
2.1 Position of the arm shaft crank on the arm shaft
Caution: Danger of injury !
Turn off the main switch.
Check and set the position of the arm shaft crank only when the
machine is switched off.
Standard checking
The arm shaft crank 1is fastened on the arm shaft 4with three
threaded pins 2.
The threaded pins must sit on the flat spot 3.
Correction
–Loosen the threaded pins 2on the arm shaft crank.
–Twist the arm shaft crank 1 on the shaft until the threaded pins 2sit
on the flat spot 3.
–Push arm shaft crank 1axially to the right as far as it will go.
–Tighten the threaded pins 2.
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1
2
3
4

2.2 Upper and lower toothed belt wheel / toothed belt
2.2.1 Position of the upper toothed belt wheel
Caution: Danger of injury !
Turn off the main switch.
Check and set the position of the upper toothed belt wheel only when
the machine is switched off.
Standard checking
The toothed belt wheel 2is fastened on the arm shaft 4with two
threaded pins.
The threaded pins must sit on the flat spot 1.
The distance between the toothed belt wheel 2 and the bobbin winder
wheel 3must amount to 0.8 mm when the bobbin winder is switched
off.
–Check distance between toothed belt wheel 2and bobbin winder
wheel 3by means of a thickness gauge.
Correction
–Loosen the threaded pins in the toothed belt wheel.
–Turn the toothed belt wheel, until the threaded pins sit on the flat
spot 1of the arm shaft 4.
–Set lateral distance of 0.8 mm between the toothed belt wheel 2
and the bobbin winder wheel 3by using a thickness gauge.
–Tighten the threaded pins in the toothed belt wheel.
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4321 32

2.2.2 Position of the lower toothed belt wheel
Caution: Danger of injury !
Turn off the main switch.
Check and set the position of the lower toothed belt wheel only when
the machine is switched off.
Standard checking
The threaded pins in the toothed belt wheel 2must sit on the flat spot 1
of the lower shaft 5.
The toothed belt wheel must be positioned in a way that the toothed
belt 4bears against the belt tensioner ring 3when the handwheel is
turned without being dislocated.
–Check the position of the toothed belt wheel.
Correction
–Pull out the toothed belt from the lower toothed belt wheel.
–Loosen the threaded pins in the toothed belt wheel.
–Turn the toothed belt wheel 2, until the screws sit on the flat spot of
the lower shaft 5.
–Tighten the threaded pins in the toothed belt wheel.
–Pull the toothed belt on the toothed belt wheel again.
–Check the course of the toothed belt.
ATTENTION: Danger of breakage !
After replacing the toothed belt, check the following: Hook adjustment
(see chapter 2.6), feeding motion of the feed dog (see chapter 2.3.4)
and lifting motion of the feed dog see chapter 2.3.5).
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2.3 Bottom feed and stitch regulator gear
2.3.1 Basic setting of stitch adjustment
Caution: Danger of injury !
Turn off the main switch.
Set the basic setting of stitch adjustment only with the sewing machine
switched off.
Standard checking
When the setting wheel 5 is in zero position, the stitch regulator gear
should have the least clearance possible.
–Set stitch length “0" at the setting wheel 5.
–Check the clearance of the stitch regulator gear at the stitch
regulator lever 1.
Correction
–Unhook the spring 2.
–Retain the setting wheel 5 using the wrench 3.
–Unscrew the screw 4 and remove the setting wheel 5.
–Turn shaft 7 to the right using a 10 mm wrench until the stitch
regulator lever 1 has the least possible clearance.
ATTENTION: Danger of breakage !
Do not turn the shaft too far to the right .
The stitch regulator parts may jam and the maximum
stitch length of 8 mm and 6 mm can no longer be achieved.
–Setscale6to“0".
–Put setting wheel 5 on again and tighten it with screw 4.
–Check the clearance of the stitch regulator lever 1.
–Put the spring 2 again.
9
GB
7
21 65 4 3

Adjust the eccentric
The eccentric 3 has to be adjusted in such a way that the mark 4 points
to the upper left and that the eccentric slot 6 stands parallel to the
threaded pin 2.
–Loosen the threaded pin 2 of the block 5.
–Through the hole 1, turn the eccentric 3 in such a way that the
mark 4 points to the upper left and that the eccentric slot 6 stands
parallel to the threaded pin 2.
–Tighten the threaded pin 2 of the block 5.
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2543 6

2.3.2 Adjust the 2nd stitch length
Caution: Danger of injury !
Turn off the main switch.
Set the basic setting of stitch adjustment only with the sewing machine
switched off.
–Set the upper setting wheel 1 to “4".
–Unscrew the screw 2 and remove the setting wheel 3.
–Using a 10 mm wrench, turn with caution the shaft 5 clockwise as
far as it will go.
–Setscale4to“4".
–Put setting wheel 3 on again and tighten it with screw 2.
11
GB
43 2 1 45

2.3.3 Position of the feed dog in the throat plate cutout
Caution: Danger of injury !
Turn off the main switch.
Check and set the position of the feed dog and stitch regulator gear
only when the machine is switched off.
–Unhook the spring 1.
–Loosen the threaded pins on the adjustment rings 8 and 9.
–Loosen screw 5.
–Align the feed dog in the center of the throat plate cutout.
–Arrest the shaft 7 with the adjustment rings 8 and 9 and tighten the
screws.
–Loosen threaded pin 10 and screw 2.
–Loosen the threaded pins on the thrust eccentric 4.
–Align the positioning frame 14 laterally so that it comes to sit in the
center between the cutouts on the shaft 7.
–Arrest the positioning frame 14 axially with the bearing bolt 6 (fixed
with screw 10) and the adjustment ring 2.
–Tighten the threaded pins on the thrust eccentric 4.
Note: The shaft 11 is fixed on surface in the positioning frame 14
at position 3 with two screws in series.
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1
2
14
98
10 11

–Turn the stitch regulator handwheel to position “0".
–Set the gear to “0".
In order to do so, turn the positioning frame 14 so that the tongues
come parallel to each other.
–Tighten the screw 13 on the block 12.
–Align the feed dog in longitudinal direction in the center of the
throat plate cutout.
–Tighten the screw 5 (see picture on page 12).
–Fit in the spring 1 (see picture on page 12) on the positioning frame
and the fastening bracket.
ATTENTION: Danger of breakage !
The shaft 11 must not reach so far into the positioning frame 14 that
the tongues are hindered in their movements.
13
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11 12 13

2.3.4 Feeding motion of the feed dog
Caution: Danger of injury !
Turn off the main switch.
Check and set the feeding motion of the feed dog only when the
machine is switched off.
Standard checking
When the machine is in position “190°” the feed dog must not
move upon actuating the stitch regulator lever if the maximum
stitch length is set.
–Set the maximum stitch length.
–Turn the machine to position “190°”.
–Move the stitch regulator lever and check whether the feed dog
stands still.
Correction
–Loosen the threaded pin on the thrust eccentric 1.
–Adjust thrust eccentric 1.
–Tighten the threaded pin on the thrust eccentric 1.
–Move the stitch regulator lever and check whether the feed dog
stands still.
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1

2.3.5 Lifting motion of the feed dog
Caution: Danger of injury !
Turn off the main switch.
Check and set the lifting motion of the feed dog only when the
machine is switched off.
Standard checking
The feed dog is supposed to have the same distance to the throat plate
at its front and backward dead center:
–Turn the handwheel and check the movement of the feed dog.
Correction
–Loosen the threaded pin on the lifting cam 1.
–Turn the lifting cam.
–Tighten the screws on the lifting cam 1.
–Check the setting.
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1

2.3.6 Feed dog height
Caution: Danger of injury !
Turn off the main switch.
Check and set the height of the feed dog only when the machine is
switched off.
Standard checking
Machines without feed dog lifting device
The feed dog should be on the same level as the throat plate.
Machines with feed dog lifting device
For a safe forward movement of the material the feed dog 2must in its
highest position be:
0.5 mm above the throat plate surface on FA machines,
0.8 mm above the throat plate surface on KFA machines.
–Turn the handwheel until the feed dog 2has reached its highest
position.
–Check the height of the feed dog 2
Correction
–Turn the handwheel until the feed dog 2has reached its highest
position.
–Loosen the screws on the lever 1.
–Turn the lever 1so that the feed dog stands 0.5 mm with FA,
respectively 0.8 mm with KFA above the throat plate surface.
–Tighten the screws on the lever 1.
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