Dürkopp Adler D867 e-con Service Instructions Manual
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Dürkopp Adler D867 e-con Service Instructions Manual

Dürkopp Adler D867 e-con Service Instructions Manual

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Summary of Contents for Dürkopp Adler D867 e-con

  • Page 1 D867 e-con Service Instructions...
  • Page 2 IMPORTANT READ CAREFULLY BEFORE USE KEEP FOR FUTURE REFERENCE All rights reserved. Property of Dürkopp Adler GmbH and protected by copyright. Any reuse of these contents, including extracts, is prohibited without the prior written approval of Dürkopp Adler GmbH. Copyright © Dürkopp Adler GmbH 2023...

  • Page 3: Table Of Contents

    Position of the hook and needle ..........52 Adjusting the hook side clearance ..........53 Adjusting the looping stroke position .......... 54 Adjusting the needle bar height ..........57 Adjusting the needle guard ............58 Service Instructions D867 e-con - 00.0 - 08/2023...
  • Page 4 Changing the upper toothed belt ..........103 17.2 Changing the lower toothed belt ..........104 Sewing motor ................109 18.1 Overview of the components ............ 109 18.2 Disassembling the sewing motor ..........110 Service Instructions D867 e-con - 00.0 - 08/2023...
  • Page 5 19.4.34 Setting the Energy Saving parameter ........ 161 19.5 Setting the Program defaults ..........162 19.6 Setting the User Configuration......... 163 19.6.1 User Management ..............165 19.6.2 Smart keys configuration ............171 19.6.3 Role Main Screen Configuration..........171 Service Instructions D867 e-con - 00.0 - 08/2023...
  • Page 6 Appendix ................. 245 25.1 Barcode examples ..............245 25.2 Converting videos for playback on the control panel ....246 25.3 Basic settings of the machine ........... 249 25.4 Wiring diagram ................. 250 Service Instructions D867 e-con - 00.0 - 08/2023...

  • Page 7: About These Instructions

    Proper setting Specifies proper setting. Disturbances Specifies the disturbances that can occur from an incorrect setting. Cover Specifies which covers must be disassembled in order to access the components to be set. Service Instructions D867 e-con - 00.0 - 08/2023...
  • Page 8 Safety ( p. 9). If no other clear location information is used in a figure, indications of right Location information or left are always from the user's point of view. Service Instructions D867 e-con - 00.0 - 08/2023...

  • Page 9: Other Documents

    European and na- tional regulations. The proper use of the built-in components is described in the corresponding manufacturer's instructions. Service Instructions D867 e-con - 00.0 - 08/2023...

  • Page 10: Liability

    Leave machines, equipment and packaging material in the condition in which they were found when the damage was discovered. This will ensure any claims against the transport company. Report all other complaints to Dürkopp Adler immediately after receiving the product. Service Instructions D867 e-con - 00.0 - 08/2023...

  • Page 11: Safety

    • Setting up the machine/putting the machine into operation • Performing maintenance work and repairs • Performing work on electrical equipment Only authorized persons may work on the machine and must first have understood these instructions. Service Instructions D867 e-con - 00.0 - 08/2023...

  • Page 12: Signal Words And Symbols Used In Warnings

    If ignored, environmental damage can result NOTICE (without hazard symbol) If ignored, property damage can result The following symbols indicate the type of danger to personnel: Symbols Icon Type of danger General Electric shock Service Instructions D867 e-con - 00.0 - 08/2023...
  • Page 13 Consequences of non-compliance. Measures for avoiding the danger.  This is what a warning looks like for a hazard that could result in moderate or minor injury if the warning is ignored. Service Instructions D867 e-con - 00.0 - 08/2023...
  • Page 14 Type and source of danger! Consequences of non-compliance. Measures for avoiding the danger.  This is what a warning looks like for a hazard that could result in property damage if ignored. Service Instructions D867 e-con - 00.0 - 08/2023...

  • Page 15: Working Basis

    3. Cut off any overlapping cable ties. NOTICE Property damage may occur! Excess cables can impair the functioning of moving machine parts. This impairs the sewing function and can result in damage. Lay excess cables as described above. Service Instructions D867 e-con - 00.0 - 08/2023...

  • Page 16: Calling Up The Service Routine

    Equal sewing foot stroke (setting an even sewing foot stroke) Sewing foot stroke Feed Move (setting the feeding foot movement)  The display shows all the values set in the selected service routine. Service Instructions D867 e-con - 00.0 - 08/2023...
  • Page 17  The machine moves to the programmed position and is switched off. The button lights up. The display shows the information that the Service Stop is active: Fig. 3: Calling up the service routine (3) 6. Make the required settings. Service Instructions D867 e-con - 00.0 - 08/2023...
  • Page 18 Fig. 5: Calling up the service routine (5) 9. Press Finish.  You are now in the service menu again. 10. Press the button.  The machine moves back to its initial position and is ready to sew. Service Instructions D867 e-con - 00.0 - 08/2023...

  • Page 19: Disassembling And Assembling The Covers

    Information Always apply 1 Nm of tightening torque when tightening the screws that are used to attach the covers. Service Instructions D867 e-con - 00.0 - 08/2023...

  • Page 20: Tilting The Machine Head

    1. Tilt the machine head as far as it will go. Erecting the machine head To erect the machine head: 1. Push the locking mechanism (1) up with one hand. 2. Erect the machine head using your other hand. Service Instructions D867 e-con - 00.0 - 08/2023...

  • Page 21: Disassembling And Assembling The Arm Cover

    To disassemble the arm cover: 1. Loosen the screws (2). 2. Disassemble the arm cover (1). Assembling the arm cover To assemble the arm cover: 1. Assemble the arm cover (1). 2. Tighten the screws (2). Service Instructions D867 e-con - 00.0 - 08/2023...

  • Page 22: Disassembling And Assembling The Front Cover (Service Cover)

    Assembling the front cover To assemble the front cover: 1. Switching off the machine 2. Place the front cover (1). Make sure not to damage the thread lever. 3. Tighten the screws (2). Service Instructions D867 e-con - 00.0 - 08/2023...

  • Page 23: Disassembling And Assembling The Head Cover

    Attention: 2 screws at the front on the head cover, 2 screws on the rear of the machine. 2. Disassemble the head cover (1). Assembling the head cover To assemble the head cover: 1. Assemble the head cover (1). 2. Tighten the screws (2). Service Instructions D867 e-con - 00.0 - 08/2023...

  • Page 24: Disassembling And Assembling The Motor Cover

    3. Disassemble the motor cover (2). Assembling the motor cover To assemble the motor cover: 1. Set the lever (3) vertical. 2. Assemble the motor cover (2). 3. Tighten the screws (1). Service Instructions D867 e-con - 00.0 - 08/2023...

  • Page 25: Disassembling And Assembling The Toothed Belt Cover

    1. Loosen the screws (1). 2. Remove the toothed belt cover (2); start by disassembling the cover from below. Fig. 12: Toothed belt cover with handwheel cover (2) ③ (3) - Plates Service Instructions D867 e-con - 00.0 - 08/2023...
  • Page 26 1. Loosen screws (5) on the handwheel (4). 2. Remove the handwheel (4). 3. Loosen the screws (1). 4. Remove the toothed belt cover (2); start by disassembling the cover from below. Service Instructions D867 e-con - 00.0 - 08/2023...
  • Page 27 (6) - Centering pin 3. Place the handwheel (4), making sure that the centering pin (6) is positioned correctly (otherwise, referencing by the hall sensor will not work properly). 4. Tighten the screws (5). Service Instructions D867 e-con - 00.0 - 08/2023...

  • Page 28: Disassembling And Assembling The Thread Tension Plate

    Make sure not to lose the bobbin case retainer (4) as it will otherwise no longer be possible to connect the push button. 4. Loosen screws (1) and (2). 5. Remove the thread tension plate (3). Service Instructions D867 e-con - 00.0 - 08/2023...
  • Page 29 2. Assemble the thread tension plate (3). 3. Tighten screws (1) and (2). 4. Slip plugs onto the PCB: • Thread clamp: Connection X10 (optional) • Thread tension: Connection X11 • Push button: Connection X12 Service Instructions D867 e-con - 00.0 - 08/2023...

  • Page 30: Opening And Closing The Throat Plate Slide

    2. Push the throat plate slide (1) apart. Closing the throat plate slide To close the throat plate slide: 1. Push the throat plate slide (1) up to the throat plate (2). Service Instructions D867 e-con - 00.0 - 08/2023...

  • Page 31: Disassembling And Assembling The Throat Plate

     Ensure that the nose (4) of the bobbin case (3) is in the cutout of the throat plate (2). 4. Tighten the screws (1). 5. Close the throat plate slide ( p. 28). 6. Finish the service routine. Service Instructions D867 e-con - 00.0 - 08/2023...

  • Page 32: Disassembling And Assembling The Feed Dog

    To assemble the feed dog: 1. Place the feed dog (1) onto the feed dog carrier (2). 2. Tighten the screws (3). 3. Insert the throat plate ( p. 29). 4. Finish the service routine. Service Instructions D867 e-con - 00.0 - 08/2023...

  • Page 33: Flats On Shafts

    This stabilizes the connection and makes adjusting easier. Important Always ensure that the screws are completely flush with the surface. The rule is to always place the 1 screw in rotational direction onto the flat. Service Instructions D867 e-con - 00.0 - 08/2023...

  • Page 34: Locking The Machine In Place

    2. Turn the handwheel carefully until the locking peg (1) slides into the slot on the arm shaft crank. Removing the lock To remove the lock: 1. Pull the locking peg (1) out of the slot in the machine arm. Service Instructions D867 e-con - 00.0 - 08/2023...

  • Page 35: Adjusting The Handwheel Into Position

    (1) is next to the marking (2). Information When the Service Stop is activated, the handwheel is easier to turn and the degree number can be read on the control panel. Service Instructions D867 e-con - 00.0 - 08/2023...
  • Page 36 Working basis Service Instructions D867 e-con - 00.0 - 08/2023...

  • Page 37: Positioning The Arm Shaft Crank On The Arm Shaft

    6. Push the arm shaft with the arm shaft crank (1) to the right as far as it will go and flush with the machine casting (3). 7. Tighten the threaded pins (2). Service Instructions D867 e-con - 00.0 - 08/2023...

  • Page 38: Performing The Basic Settings Of The Eccentrics

    The looping stroke securing position (at approx. 202°) allows you to define the basic settings for the sewing foot stroke, the feed dog lift and the`feed dog movement. Proper setting The markings on each eccentric are positioned correctly relative to one another. Service Instructions D867 e-con - 00.0 - 08/2023...
  • Page 39 4. Press the Service Stop button. 5. Tilt the machine head. 6. Loosen the screws (3). 7. Turn the eccentric such that slot (1) lines up with slot (2). 8. Tighten the screws (3). Service Instructions D867 e-con - 00.0 - 08/2023...
  • Page 40 To adjust the eccentric for the feed dog movement: 9. Loosen the screws (6). 10. Turn the eccentric such that slot (4) lines up with slot (5). 11. Tighten the screws (6). Service Instructions D867 e-con - 00.0 - 08/2023...
  • Page 41 17. Lock the machine in place at the looping stroke position ( p. 32). 18. Tighten the first screw (9) in the direction of rotation. 19. Remove the lock. 20. Turn the eccentric and tighten the screw (8). Service Instructions D867 e-con - 00.0 - 08/2023...

  • Page 42: Adjusting The Compensating Weight

    2. Adjust the compensating weight (2) such that screw (1) and screw (4) are at the same height. Make sure there is a gap between the compensating weight (2) and the transmission lever (3). 3. Tighten the screw (1). Service Instructions D867 e-con - 00.0 - 08/2023...

  • Page 43: Adjusting The Mechanical Stitch Adjustment

    0 = no feed) is determined by the Calibration zero stitch ( p. 182). Cover • Remove the toothed belt cover ( p. 23) • Motor cover ( p. 22) • Remove the front cover ( p. 20) Service Instructions D867 e-con - 00.0 - 08/2023...
  • Page 44 3. Pull the cables out of the cable ducts (4). While doing so, make sure not to damage the cables. 4. Insert the locking peg (∅ 5 mm) (2) into the hole (3) on the motor bracket. Service Instructions D867 e-con - 00.0 - 08/2023...

  • Page 45: Adjusting The Forward And Backward Stitch

    The forward and backward stitch are controlled by a stepper motor and adjusted via software. The calibration is performed only in the software and does not require that you mechanically set an eccentric ( p. 182). Service Instructions D867 e-con - 00.0 - 08/2023...

  • Page 46: Adjusting Feed Dog And Needle Bar Linkage

    Information Details on the settings of the Feed dog feed movement, the feed dog lift and the compensating weight are provided in the chapter Basic settings of the eccentrics ( p. 36). Service Instructions D867 e-con - 00.0 - 08/2023...

  • Page 47: Adjusting The Lateral Feed Dog Position

    8. Check the feed dog position and readjust it if necessary. If this is not sufficient, move the entire feed dog carrier on the pusher shaft ( p. 46). 9. Finish the service routine. Service Instructions D867 e-con - 00.0 - 08/2023...

  • Page 48: Moving The Feed Dog Carrier Sideways

    7. Push the set collars (2) toward each other as far as they will go. Important Make sure that the pusher shaft is tightened by the set collars and does not have any axial play. 8. Tighten the screw (4). 9. Tighten the threaded pins (3). Service Instructions D867 e-con - 00.0 - 08/2023...

  • Page 49: Aligning The Needle Bar Linkage Sideways

    4. Disassemble the tensioning plate ( p. 26). 5. Position the plates (4) of the stitch regulator flush. 6. Loosen the threaded pins (1) on the set collars (2). 7. Loosen the screw (3). Service Instructions D867 e-con - 00.0 - 08/2023...
  • Page 50 Make sure that the thread lever (9) does not collide with other parts when moving. 14. Tighten the threaded pins (8). Order Then, check the following settings: • Distance between hook and needle ( p. 53) • Looping stroke position ( p. 54) Service Instructions D867 e-con - 00.0 - 08/2023...

  • Page 51: Aligning The Needle Bar Linkage In The Sewing Direction

    6. Move the needle bar linkage until there is a distance of 10 mm between presser bar and walking foot bar. 7. Tighten the screw (1). 8. Finish the service routine. 9. Assemble the front cover. Service Instructions D867 e-con - 00.0 - 08/2023...

  • Page 52: Aligning The Feed Dog In Sewing Direction

    8. Align the feed dog in the sewing direction such that the needle pierces in the center of the needle hole. 9. Tighten the screw (1). Order Next, check the feed movement to the throat plate cutout at the maximum stitch length. Service Instructions D867 e-con - 00.0 - 08/2023...

  • Page 53: Adjusting The Feed Dog Height At Top Dead Center

    6. Turn the lever (2) such that the upper edge of the feed dog protrudes 0.5 mm (KFA = 0.8 mm) above the throat plate. 7. Tighten the threaded pins (1). 8. Finish the service routine. Service Instructions D867 e-con - 00.0 - 08/2023...

  • Page 54: Position Of The Hook And Needle

    Check and, if necessary, readjust the distance to the hook tip after inserting a new needle with a different size. Service Instructions D867 e-con - 00.0 - 08/2023...

  • Page 55: Adjusting The Hook Side Clearance

    2. Lock the machine in place ( p. 32). 3. Open the throat plate slide ( p. 28). 4. Tilt the machine head ( p. 18). 5. Loosen the screws (4). 6. Loosen the threaded pin (2). Service Instructions D867 e-con - 00.0 - 08/2023...

  • Page 56: Adjusting The Looping Stroke Position

    • Needle bar linkage is aligned correctly ( p. 47), ( p. 49) Fig. 39: Adjusting the looping stroke position (1) ① ② (1) - Vertical center line of the needle (2) - Hook tip Service Instructions D867 e-con - 00.0 - 08/2023...
  • Page 57  The hook tip (2) points to the vertical center line of the needle (1). 12. Tighten the threaded pin (6). 13. Tighten the threaded pins (5) on the flat (4). 14. Remove the lock ( p. 32). 15. Finish the service routine. Service Instructions D867 e-con - 00.0 - 08/2023...
  • Page 58 • Position of the needle guard ( p. 57) • Timing of cutting by the thread trimmer ( p. 82); ( p. 98) • A needle with the correct needle strength has been inserted Service Instructions D867 e-con - 00.0 - 08/2023...

  • Page 59: Adjusting The Needle Bar Height

    The hook tip is level with the lower third of the groove on the needle. To adjust the needle bar height: 1. Execute the service routine Needle-Hook > Timing ( p. 14).  The software is used to define the necessary presettings on the machine. Service Instructions D867 e-con - 00.0 - 08/2023...

  • Page 60: Adjusting The Needle Guard

    To adjust the needle guard: 1. Execute the service routine Needle-Hook > Timing ( p. 14).  The software is used to define the necessary presettings on the machine. Service Instructions D867 e-con - 00.0 - 08/2023...
  • Page 61 (1) far away enough so that it cannot be touched by the hook tip. • For pushing away more: Turn screw (2) counterclockwise • For pushing away less: Turn screw (2) clockwise 6. Finish the service routine. Service Instructions D867 e-con - 00.0 - 08/2023...

  • Page 62: Adjusting The Bobbin Case Lifter

    • Formation of loops on the bottom side of the seam • Loud machine noise Information You will also find videos for the settings at the bobbin case lifter on Dürkopp Adler’s YouTube channel. Service Instructions D867 e-con - 00.0 - 08/2023...

  • Page 63: Adjusting The Lifting Gap

    6. Set the bobbin case lifter (6) so that the gap between the nose of the bobbin case (1) and the slot in the throat plate (2) is just large enough to allow the needle thread to slip through without a problem. Service Instructions D867 e-con - 00.0 - 08/2023...

  • Page 64: Adjusting The Timing For Lifting

    5. Use the allen key to turn the control cam (3) so that the bobbin case lifter opens at the correct point in time. 6. Tighten the threaded pin (4). 7. Insert the plug (1) into the opening. 8. Perform a sewing test. Service Instructions D867 e-con - 00.0 - 08/2023...

  • Page 65: Sewing Feet

    Spring pressure always keeps the gear securely in the zero position on the control cam. Order First, check the following setting: • Basic setting of the eccentrics for sewing foot stroke, feed dog lift and feed dog movement ( p. 36) Service Instructions D867 e-con - 00.0 - 08/2023...
  • Page 66 8. Loosen all plugs from the PCB (3). 9. Remove the PCB (3) CAREFULLY. While doing so, press the spacers (4) together individually (using a suitable tool if necessary) and lift the PCB (3) gradually. Service Instructions D867 e-con - 00.0 - 08/2023...
  • Page 67 11. Loosen the threaded pin (6). Check if the threaded pin underneath is seated firmly on the flat. If not, tighten the threaded pin so that there is no play. 12. Tighten the threaded pin (6). Service Instructions D867 e-con - 00.0 - 08/2023...
  • Page 68 15. Use your hand to test if the gear (7) is pushed to the 0 position by the spring. 16. Assemble the PCB (3) again. 17. Attach the plug at the PCB (3). 18. Place the cover (1) of the PCB. 19. Connect the plug (2). Service Instructions D867 e-con - 00.0 - 08/2023...

  • Page 69: Adjusting An Even Sewing Foot Stroke

    To set an even sewing foot stroke: 1. Switch off the machine. 2. Disassemble the arm cover ( p. 19). 3. Set the feed dog to the level of the throat plate. 4. Loosen the screw (3). Service Instructions D867 e-con - 00.0 - 08/2023...

  • Page 70: Adjusting The Sewing Foot Pressure And Sewing Foot Lift

    4. Readjust if necessary. 10.3 Adjusting the sewing foot pressure and sewing foot lift Fig. 54: Adjusting the sewing foot pressure and sewing foot lift (1) ① (1) - Locking peg Service Instructions D867 e-con - 00.0 - 08/2023...
  • Page 71 (7) - Curve (6) - Screw (8) - Roller 6. Loosen the screw (6). 7. Turn the curve (7) until the roller (8) is seated in the recess of the curve (7). Service Instructions D867 e-con - 00.0 - 08/2023...
  • Page 72 When the pedal is pressed completely back, the sewing feet will be raised after the thread is cut so that the sewing material can be removed. Service Instructions D867 e-con - 00.0 - 08/2023...

  • Page 73: Adjusting The Needle Thread Tension

    • Higher needle thread tension: thick sewing material, high thread strengths Proper setting The loop of the needle thread slides at low tension over the thickest point of the hook, without forming loops or snagging. Service Instructions D867 e-con - 00.0 - 08/2023...
  • Page 74 • Reduce the needle thread tension: Slide the needle thread regulator (3) to the left • Increase the needle thread tension: Slide the needle thread regulator (3) to the right 5. Tighten screws (1) and (2). Service Instructions D867 e-con - 00.0 - 08/2023...

  • Page 75: Adjusting The Thread Tensioning Spring

    2. Slide the stop (2) to adjust the spring travel. • Longer spring travel: Slide the stop (2) down. • Shorter spring travel: Slide the stop (2) up. 3. Tighten the screw (3). Service Instructions D867 e-con - 00.0 - 08/2023...

  • Page 76: Adjusting The Spring Tension

    • Greater spring tension: Turn screw (4) counterclockwise • Less spring tension: Turn screw (4) clockwise  The scale (2) of the spring balance (1) indicates the thread tension reading. 5. Tighten the knurled nut (3). Service Instructions D867 e-con - 00.0 - 08/2023...

  • Page 77: Bobbin Winder

    2. To fine-tune the setting, put a completely filled bobbin onto the winder. 3. Press the winder lever (2) up to the thread as far as it will go by turning the threaded pin (2). Service Instructions D867 e-con - 00.0 - 08/2023...

  • Page 78: Adjusting The Winder Filling Quantity

    To keep the thread from overflowing on the bobbin, observe the following setting tolerances: • Bobbin Ø 32 mm: Ø 31 ± 0.5 mm • Bobbin Ø 28 mm: Ø 27 ± 0.5 mm Service Instructions D867 e-con - 00.0 - 08/2023...

  • Page 79: Adjusting The Bobbin Thread Guide

    Turn the bobbin thread guide (2) to the front • To wind on the bobbin thread further to the rear: Turn the bobbin thread guide (2) to the rear 3. Tighten the screw (1). Service Instructions D867 e-con - 00.0 - 08/2023...

  • Page 80: Thread Trimmer (Fa)

    ③ ⑦ ⑥ ③ ⑤ ④ (1) - Counter blade (5) - Screw (2) - Thread-pulling knife (6) - Hook bearing (3) - Threaded pin (7) - Set collar (4) - Lever Service Instructions D867 e-con - 00.0 - 08/2023...

  • Page 81: Adjusting The Cutoff Curve

    ① ④ (1) - Roller (5) - Threaded pin (2) - Set collar (6) - Widest extent (3) - Threaded pins (7) - Lever (4) - Control cam (8) - Clamping screw Service Instructions D867 e-con - 00.0 - 08/2023...
  • Page 82 • Push the control cam (4) up against the roller (1) • Push the set collar (2) up against the control cam (4) • Tighten the threaded pins (3) 10. Tighten the threaded pins (5). Service Instructions D867 e-con - 00.0 - 08/2023...
  • Page 83 15. Push the set collar (2) to the right as far as it will go and against the control cam (4). 16. Check the looping stroke position ( p. 54). 17. Tighten the threaded pins (3). Service Instructions D867 e-con - 00.0 - 08/2023...

  • Page 84: Adjusting The Cutting Pressure

    Disturbances caused by an incorrect setting: • Increased knife wear when the pressure is too great • Problems when sewing on if the clamping pressure is too high • Problems in cutting the thread Service Instructions D867 e-con - 00.0 - 08/2023...

  • Page 85: Adjusting Point In Time For Cutting

    (3) - Control cam (7) - Threaded pins (4) - Marking End position Proper setting The threads are cut when the thread lever is at the top dead center (hand- wheel position 60°). Service Instructions D867 e-con - 00.0 - 08/2023...
  • Page 86 • Insert the thread into the thread-pulling knife (5) and slowly turn the handwheel • Check the handwheel position at which the thread is cut  The thread must be cut at 60°. 11. Readjust if necessary. Service Instructions D867 e-con - 00.0 - 08/2023...

  • Page 87: Short Thread Trimmer (Kfa)

    Cover • Open the throat plate slide ( p. 28) • Disassemble the throat plate ( p. 29) • Disassemble the feed dog ( p. 30) Service Instructions D867 e-con - 00.0 - 08/2023...

  • Page 88: Adjusting The Height And Initial Position Of The Thread-Pulling Knife

    1. Fit the counter blade (10) on the knife carrier (8) and push it up against the thread-pulling knife (12) without pressure. 2. Tighten the screw (9). 3. Loosen the screw (4). 4. Loosen the threaded pin (7). Service Instructions D867 e-con - 00.0 - 08/2023...
  • Page 89 The knife carrier has no axial play, but can still run smoothly. 4. Tighten the screw (4). 5. Engage the latch (2). 6. Check the position of the thread-pulling knife (12) and readjust it if necessary. Service Instructions D867 e-con - 00.0 - 08/2023...

  • Page 90: Adjusting The Locking Latch

    (1) catches.  If the locking latch (1) does not reach all the way to the bolt (5) when catching, adjust the control sideways ( p. 89). Service Instructions D867 e-con - 00.0 - 08/2023...

  • Page 91: Adjusting The Control Cam Sideways

    5. Screw in the threaded pin (8) until the distance between roller (3) and control cam (7) is 0.1 ± 0.05 mm.  The threaded pin (8) abuts on the set collar (5). Service Instructions D867 e-con - 00.0 - 08/2023...

  • Page 92: Adjusting The Bobbin Case Support

    2. Turn the counter blade support (2) with the bobbin case support (1) until the front edge of the bobbin case support (1) is flush with the nose of the bobbin case. 3. Tighten the screw (3). Service Instructions D867 e-con - 00.0 - 08/2023...

  • Page 93: Adjusting The Cutting Pressure

    3. Place the counter blade (3) in position against the thread-pulling knife (1). 4. Tighten the screw (4). 5. Check if the setting is now as specified above - if NOT, adjust the setting again. Service Instructions D867 e-con - 00.0 - 08/2023...

  • Page 94: Adjusting Point In Time For Cutting

    6. Use the handwheel to turn the machine until the thread is cut shortly before reaching the marking (2). 7. Check if the thread was cut at the 65° position on the handwheel. Service Instructions D867 e-con - 00.0 - 08/2023...
  • Page 95 2. Move the control cam (5) towards the set collar (4) until it makes contact and correct the position of the control cam (5) by turning. 3. Tighten the threaded pins (6) on the control cam (5). 4. Check and, if necessary, correct the cutting position. Service Instructions D867 e-con - 00.0 - 08/2023...

  • Page 96: Long Thread Trimmer (Lfa)

    Fig. 76: Adjusting the height of the thread-pulling knife ① ② ③ ④ ⑤ ⑥ (1) - Counter blade (4) - Knife carrier (2) - Thread-pulling knife (5) - Set collar (3) - Screws (6) - Screw Service Instructions D867 e-con - 00.0 - 08/2023...

  • Page 97: Adjusting The Cutoff Curve

    (1) - Roller (6) - Widest extent (2) - Set collar (7) - Lever (3) - Threaded pins (8) - Clamping screw (4) - Control cam (9) - Solenoid (5) - Threaded pin Service Instructions D867 e-con - 00.0 - 08/2023...
  • Page 98 15. Push the set collar (2) to the right as far as it will go and against the control cam (4). 16. Check the looping stroke position ( p. 54). 17. Tighten the threaded pins (3). Service Instructions D867 e-con - 00.0 - 08/2023...

  • Page 99: Adjusting The Cutting Pressure

    2. Turn the handwheel until the thread-pulling knife (4) can be swung out by hand. 3. Loosen the screw (1). 4. Loosen screws (6) on the hook thread clamp (3). 5. Loosen the screws (5). Service Instructions D867 e-con - 00.0 - 08/2023...

  • Page 100: Adjusting Point In Time For Cutting

    1. Tilt the machine head ( p. 18). 2. Open the throat plate slide ( p. 28). 3. Loosen the threaded pins (6). 4. Turn the handwheel until the thread-pulling knife (4) can be swung out by hand. Service Instructions D867 e-con - 00.0 - 08/2023...
  • Page 101 • Insert the thread into the thread-pulling knife (4) and slowly turn the handwheel • Check the handwheel position at which the thread is cut  The thread must be cut at 60°. 11. Readjust if necessary. Service Instructions D867 e-con - 00.0 - 08/2023...

  • Page 102: Adjusting The Safety Release Clutch

    When the safety release clutch is engaged, threaded pins (1) and (2) are parallel to each other (figure above). When the safety release clutch is disengaged, threaded pins (1) and (2) are not parallel to each other. Service Instructions D867 e-con - 00.0 - 08/2023...
  • Page 103 3. Turn the handwheel until the pin (4) slides into the slot on the set collar (5). 4. Continue to turn the handwheel until the safety release clutch engages with an audible click. Service Instructions D867 e-con - 00.0 - 08/2023...

  • Page 104: Adjusting The Torque

    3. Using the screw driver, turn the washer on the slot (1) so that 8 Nm is reached for the torque. • Increase force: turn in the + direction • Decrease force: turn in the - direction 4. Tighten the screw (3). Service Instructions D867 e-con - 00.0 - 08/2023...

  • Page 105: Toothed Belt

    Fig. 83: Changing the upper toothed belt (1) ① ② (1) - Tensioning roller (2) - Screw 6. Loosen the screw (2) on the tensioning roller (1).  The toothed belt tension is slack. Service Instructions D867 e-con - 00.0 - 08/2023...

  • Page 106: Changing The Lower Toothed Belt

    2. Disassemble the front cover ( p. 20). 3. Disassemble the arm cover ( p. 19). 4. Disassemble handwheel and toothed belt cover ( p. 23). 5. Disassemble the motor cover ( p. 22). Service Instructions D867 e-con - 00.0 - 08/2023...
  • Page 107 • CAN cable (7) 7. Pull the cable (9) out of the terminals. 8. Loosen the screws (1). 9. Remove the holder (8) with the PCB. Important Make sure not to lose the nut (6). Service Instructions D867 e-con - 00.0 - 08/2023...
  • Page 108  The toothed belt tension is slack. 14. Remove the tensioning roller (10). Make sure not to lose the washer. 15. Remove the toothed belt (13). 16. Tilt the machine head. 17. Remove the toothed belt (11). Service Instructions D867 e-con - 00.0 - 08/2023...
  • Page 109 25. Erect the machine head. Fig. 88: Changing the lower toothed belt (4) ⑬ ⑩ ⑭ (10) - Tensioning roller (14) - Screw (13) - Toothed belt Service Instructions D867 e-con - 00.0 - 08/2023...
  • Page 110 • Cable thread trimmer (4) (optional), slot X11 • Cable thread trimmer (5), slot X12 • CAN cable (7), slot X1 34. Clamp the cable (9) into the terminals. 35. Assemble the covers. Service Instructions D867 e-con - 00.0 - 08/2023...

  • Page 111: Sewing Motor

    Fig. 90: Overview of the components ⑥ ① ⑤ ④ ② ③ (1) - Support plate (4) - Toothed belt (2) - Motor (5) - Handwheel (3) - Toothed belt wheel (6) - Tensioning roller Service Instructions D867 e-con - 00.0 - 08/2023...

  • Page 112: Disassembling The Sewing Motor

     The toothed belt tension is slack. 7. Remove the tensioning roller (1). Make sure not to lose the washer. Fig. 92: Disassembling the sewing motor (2) ③ (3) - Toothed belt 8. Remove the toothed belt (3). Service Instructions D867 e-con - 00.0 - 08/2023...
  • Page 113 11. Remove the support plate (5) together with the motor. Fig. 94: Disassembling the sewing motor (4) ⑨ ⑧ (8) - Toothed belt wheel (9) - Threaded pin 12. Loosen the threaded pin (9) on the toothed belt wheel (8). Service Instructions D867 e-con - 00.0 - 08/2023...

  • Page 114: Assembling The Sewing Motor

    15. Pull off the motor (7) and replace it with a new one ( p. 112). 18.3 Assembling the sewing motor NOTICE Property damage may occur! Possible damage to the PCB. Make sure the toothed belt runs straight and along the center of the toothed belt wheels. Service Instructions D867 e-con - 00.0 - 08/2023...
  • Page 115 3. Tighten the toothed belt wheel (3) using the threaded pin (6) and check for smooth movement. 4. Lay the cables (5) from the motor (4) through the tabletop and insert the plugs into the marked slots on the control. Service Instructions D867 e-con - 00.0 - 08/2023...
  • Page 116 Fig. 99: Assembling the sewing motor (4) ⑧ (8) - Toothed belt 6. Place the toothed belt (8). Fig. 100: Assembling the sewing motor (5) ⑨ ⑩ (9) - Tensioning roller (10) - Screw Service Instructions D867 e-con - 00.0 - 08/2023...
  • Page 117 10. Assemble the toothed belt cover with large handwheel ( p. 24). Make sure the centering pin is seated correctly on the handwheel, as the hall sensor will otherwise not be able to complete referencing properly. Service Instructions D867 e-con - 00.0 - 08/2023...
  • Page 118 Sewing motor Service Instructions D867 e-con - 00.0 - 08/2023...

  • Page 119: Programming

     This opens the navigation interface. Fig. 101: Logging in as a technician (1) ① (1) - Logout 2. Press Logout (1).  This opens the login interface. Fig. 102: Logging in as a technician (2) Service Instructions D867 e-con - 00.0 - 08/2023...

  • Page 120: Log In User

     This opens the login interface. Fig. 104: Log in user (2) There are three ways to log in. The three options - including the necessary settings in the software - are described below. Service Instructions D867 e-con - 00.0 - 08/2023...

  • Page 121: Logging In With Username And Password

    (1) - NFC chip (2) - Arm cover Assigning an NFC tag to a user To assign an NFC tag to a user: 1. Select a user in User Management or create a new user. Service Instructions D867 e-con - 00.0 - 08/2023...

  • Page 122: Login With Usb Key

    To log in with a USB key: 1. Plug the assigned USB key into the control panel.  If the USB key has been assigned correctly, the user will be logged in. Service Instructions D867 e-con - 00.0 - 08/2023...

  • Page 123: Login With File On Usb Key

    Once the user with the assigned file stored on a USB key has been created on every machine, login will be possible with a copy of the file stored on any USB key. Service Instructions D867 e-con - 00.0 - 08/2023...
  • Page 124 1. Plug the USB key holding the file into the control panel. 2. Enter username and password.  If the file on the UBS key has been assigned correctly, the user will be logged in. Service Instructions D867 e-con - 00.0 - 08/2023...

  • Page 125: Defining General Settings (Technician Access)

     This opens the navigation interface. Fig. 106: Defining general settings (1) ① (1) - Settings 2. Press Settings (1).  This opens the Settings interface. Fig. 107: Settings Service Instructions D867 e-con - 00.0 - 08/2023...
  • Page 126  p. 125 Machine Configuration  p. 162 Program defaults  p. 163 User Configuration  p. 173 Manual Data Transfer  p. 180 Service  p. 200 Information  p. 203 Software update Service Instructions D867 e-con - 00.0 - 08/2023...

  • Page 127: Setting The Machine Configuration

    Sewing foot stroke  p. 139 Stitch length  p. 141 RFW/SSD  p. 142 Needle thread monitor  p. 144 Needle thread tension sensor  p. 144 Holding force  p. 145 Pedal Service Instructions D867 e-con - 00.0 - 08/2023...
  • Page 128  p. 153 Threading mode  p. 153 Operation lock  p. 154 Manual bartack  p. 154 Jog dial  p. 154 Referencing  p. 155 Function modules  p. 155 Scanner Service Instructions D867 e-con - 00.0 - 08/2023...

  • Page 129: Setting The Thread Trimmer Parameters

    Needle position when sewing stops during 000 - 359 [°] the seam, specified in degrees • Value range Needle position after thread 000 - 359 [°] trimming Needle position after thread cutting before reversal. Service Instructions D867 e-con - 00.0 - 08/2023...
  • Page 130 00 - 99 [stitches] Number of short stitches at seam • Value range 00 - 99 [stitches] Stitch length • Value range -12.0 – 12.0 [mm] recommended value range: 0.1 – 1.5 [mm] Service Instructions D867 e-con - 00.0 - 08/2023...
  • Page 131 • Value range 000 - 359 [°] Position of the needle when the change of stitch length is deactivated. • Value range 000-359 [°] • Value range Thread trimming backward stitch On/Off Service Instructions D867 e-con - 00.0 - 08/2023...
  • Page 132 • Value range 000 - 600 [s] Duty cycle t2 Duty cycle in time period t2. • Value range 000 - 100 [%] Boost • Value range On/Off Service Instructions D867 e-con - 00.0 - 08/2023...

  • Page 133: Setting The Needle Thread Clamp Parameters

    0 = at seam beginning only 1 = seam beginning + during turn back 2 = seam beginning + during sewing foot lift 3 = seam beginning + during turn back + sewing foot lift Service Instructions D867 e-con - 00.0 - 08/2023...
  • Page 134 000 - 359 [°] Clamp For Knife Off • Value range 000 - 359 [°] Exhaust On • Value range 000 - 359 [°] Exhaust Off • Value range 00000 – 99999 [ms] Service Instructions D867 e-con - 00.0 - 08/2023...

  • Page 135: Setting The Sewing Speed Parameters

    Reduction of the speed to 3000 (rpm) in 150-9999 [rpm] combination with an activated input signal • Value range Speed limitation DB2000 Reduction of the speed to 2000 (rpm) in 150-9999 [rpm] combination with an activated input signal Service Instructions D867 e-con - 00.0 - 08/2023...

  • Page 136: Setting The Stop Positions Parameters

    000 - 359 [°] • Value range Length Pos. - Signal 000 - 359 [°] • Value range Change speed on position On/Off • Value range Position of speed change 000 - 330 [°] Service Instructions D867 e-con - 00.0 - 08/2023...

  • Page 137: Setting The Sewing Foot Lift Parameters

    Mode 2 The needle thread tension is lifted after thread cutting Mode 3 The needle thread tension is lifted as the sewing feet are lifted during sewing and after thread cutting Service Instructions D867 e-con - 00.0 - 08/2023...
  • Page 138 • Value range On/Off thread tension State After thread trimming • Value range Unchanged/Off/On State After power • Value range Unchanged/Off/On • Value range Thread tension open at service Off/On stop Service Instructions D867 e-con - 00.0 - 08/2023...

  • Page 139: Setting The Sewing Foot Stroke Parameters

    • Value range 0000 - 4000 [rpm], depending on sub- class Quick stroke adjustment in tack Setting becomes visible at a Speed level of 10 [rpm]. • Value range On/Off Service Instructions D867 e-con - 00.0 - 08/2023...
  • Page 140 • Value range 00.0 – 09.0 [mm] Max. Sewing foot stroke Sewing foot stroke at which the reduced speed is reached. • Value range 00.0 – 09.0 [mm] Service Instructions D867 e-con - 00.0 - 08/2023...

  • Page 141: Setting The Stitch Length Parameters

    MUST be adjusted subclass when changing the sewing equipment. • Value range Manual stitch length adjustment Stitch regulator for manual adjustment of On/Off the stitch length active or inactive; optional equipment. Service Instructions D867 e-con - 00.0 - 08/2023...
  • Page 142 Value range 1.0 - 12.0 [mm], depending on subclass stitch length State After thread trimming • Value range Unchanged/Off/On State After power • Value range Unchanged/Off/On Service Instructions D867 e-con - 00.0 - 08/2023...

  • Page 143: Setting The Rfw/Ssd Parameters

    SSD. • Value range 0.0 - 4.0 Values only apply to RFW Intensity the remaining thread monitor, not the SSD. • Value range 0.0 - 4.0 • Value range Sewing stop On/Off Service Instructions D867 e-con - 00.0 - 08/2023...

  • Page 144: Setting The Needle Thread Monitor Parameters

    Menu items Value range On/Off Right side Speed • Value range 0050 - 1000 [rpm] Stitch delay • Value range 000 - 255 [stitches] Debouncing • Value range 0000 – 5000 [ms] Service Instructions D867 e-con - 00.0 - 08/2023...
  • Page 145 Menu items Value range Bobbin Active • Value range On/Off Delay • Value range 0.00 - 2.55 [s] Debouncing • Value range 0.00 - 2.55 [s] • Value range Sewing stop On/Off Service Instructions D867 e-con - 00.0 - 08/2023...

  • Page 146: Setting The Needle Thread Tension Sensor Parameters

    Only visible for Mode On Max. Current Holding current of the motor • Value range 00 - 50 Only visible for Mode On Response Response time for the continuous current • Value range 000 - 100 Service Instructions D867 e-con - 00.0 - 08/2023...

  • Page 147: Setting The Pedal Parameters

    000 – 255 [ms] 19.4.14 Setting the Pedal 2 parameters If the second pedal is activated, the setting options shown will be the same as under Setting the Pedal parameters ( p. 145). Service Instructions D867 e-con - 00.0 - 08/2023...

  • Page 148: Setting The Needle Cooling Parameters

    • Value range 00.0 - 10.0 [s] Only visible for Mode Cool Speed Speed at which the needle cooling is acti- Related to sewing vated. speed • Value range 0000 - 6000 [rpm] Service Instructions D867 e-con - 00.0 - 08/2023...

  • Page 149: Setting The Puller Parameters

    The upper roller runs run. actively under power. Top + Bottom Both wheels run actively under power. constant = even Feeding method transport intermittent = trans- port adapted to the rhythm of the feed dog Service Instructions D867 e-con - 00.0 - 08/2023...
  • Page 150 • Value range 0.0 - 5.0 [A] Diameter • Value range 0000 – 9999 [mm] Direction 0 (X) = right  ) = left Closed Loop 0 (X) = non-regulated  ) = regulated Service Instructions D867 e-con - 00.0 - 08/2023...
  • Page 151 • Value range 0.0 - 5.0 [A] Diameter • Value range 0000 – 9999 [mm] Direction 0 (X) = right  ) = left Closed Loop 0 (X) = non-regulated  ) = regulated Service Instructions D867 e-con - 00.0 - 08/2023...

  • Page 152: Setting The Edge Guide Parameters

    Smallest possible gap between the sewing 00.1 – 36.0 [mm] foot and the edge guide. The smallest possible distance depends on the sewing equipment and MUST be adapted after a change of the sewing equipment. Service Instructions D867 e-con - 00.0 - 08/2023...

  • Page 153: Setting The Material Thickness Detection Parameters

    Only visible for Fabric compensation in bartack Material thickness detection active • Value range On/Off • Value range Perfect Quality Sensor (PGS) On/Off active Service Instructions D867 e-con - 00.0 - 08/2023...

  • Page 154: Setting The Correction Speed Effect Parameters

    On: A seam is started with the pedal and then completed automatically at a defined sewing speed until the end of the material is detected • Value range Debouncing 0.00 - 2.55 [s] Service Instructions D867 e-con - 00.0 - 08/2023...

  • Page 155: Setting The Seam Segment Mode Parameters

    (On). • Value range Stitch length Manual stitch length adjustment with active On/Off operation lock • Value range All Inputs All inputs active during machine blockage. On/Off Service Instructions D867 e-con - 00.0 - 08/2023...

  • Page 156: Setting The Manual Bartack Parameters

    After the machine was switched on, the stepper motors need to perform a reference run. Depending on the setting, referencing can be performed automatically or by pressing the pedal back all the way. Icon Menu items Value range • Value range User start referencing manual On/Off Service Instructions D867 e-con - 00.0 - 08/2023...

  • Page 157: Setting The Function Modules Parameter

    Barcode identification active On/Off The following types of barcodes can be read using the scanner: • Code 128 • UCC EAN 128 • Code 39 The barcode types can be created with freeware software. Service Instructions D867 e-con - 00.0 - 08/2023...

  • Page 158: Setting The Rfid Scanner Parameters

    Only visible for Desk height 000.0 - 140.0 adjustment enable 19.4.31 Setting the Interface parameters The interfaces can be used for the scanner. The parameter is active if a scanner is connected. Service Instructions D867 e-con - 00.0 - 08/2023...

  • Page 159: Setting The Module Management Parameters

    DAC Flex control and at input and output modules 1 and 2. If connected correctly, any additional modules or PCBs, e.g. the stepper motor module, will appear for checking under Module management. Fig. 108: Module management Service Instructions D867 e-con - 00.0 - 08/2023...
  • Page 160 Program selection Bit B0 - B9 Program selection by an external device Short stitch  p. 127 edge guide position (height)  p. 150 edge guide position (gap and height)  p. 150 DB3000  p. 133 Service Instructions D867 e-con - 00.0 - 08/2023...
  • Page 161 Edge Guide Check Up/Down Operating Instructions Left needle bar Right needle bar Automatic stitch length adjustment Poka yoke 1-4 result Short stitch Each input can be switched to stored or not stored. Service Instructions D867 e-con - 00.0 - 08/2023...
  • Page 162 Output active while the machine is in the seam Segment Output 01 - 16 Manual bartack Push button signal Stitch done Motor blockage (operation lock)  p. 153 Short stitch  p. 162 Edge guide Operating Instructions/ p. 150 Service Instructions D867 e-con - 00.0 - 08/2023...

  • Page 163: Setting The Authentication Methods Parameters

    Allow login with file on USB key • Value range On/Off 19.4.34 Setting the Energy Saving parameter Icon Menu items Value range • Value range Energy Saving delay 0000 - 2400 [s] Service Instructions D867 e-con - 00.0 - 08/2023...

  • Page 164: Setting The Program Defaults

    Off/Up/Down Reset Enter the value to which the daily piece counter is set when a reset is performed. • Value range -999 - 999 Stitch functions • Value range Count stitches On/Off Service Instructions D867 e-con - 00.0 - 08/2023...

  • Page 165: Setting The User Configuration

    Abort in repair mode Direct abort 19.6 Setting the User Configuration Settings can be made here that are designed to make working on the machine in various external conditions easier for the user. Service Instructions D867 e-con - 00.0 - 08/2023...
  • Page 166  Operating Instruc- Manual mode tions Main screen configuration  Operating Instruc- Manual mode tions Status bar configuration Role Main Screen Configuration  p. 171 Role Status Bar Configuration  p. 172 Service Instructions D867 e-con - 00.0 - 08/2023...

  • Page 167: User Management

    If, for instance, a role is derived from a Technician (default role), the new role will initially have all of the same authorizations as the original role. You will afterwards be able to adjust the authorizations for the new role using the drop-down menu. Service Instructions D867 e-con - 00.0 - 08/2023...
  • Page 168 Activate/deactivate access to the Role Status Bar function Access Activate/deactivate access to the Switch to automatic mode function Access Activate/deactivate access to the Parameter View function Access Activate/deactivate Edit the Manual bartack function Edit Service Instructions D867 e-con - 00.0 - 08/2023...
  • Page 169 Activate/deactivate Edit the Sewing foot pressure function Edit Activate/deactivate Edit the Sewing foot stroke function Edit Activate/deactivate Edit the Switch foot stroke alterna- tion function Edit Activate/deactivate Edit the Bartack toggle function Edit Service Instructions D867 e-con - 00.0 - 08/2023...
  • Page 170 Activate/deactivate Edit the Needle thread tension factor Edit Activate/deactivate Edit the Tiles enabled function Edit Sewing Activate/deactivate Edit the Enable multi functional tiles function Edit User Management Activate/deactivate Edit the Current user role Edit Service Instructions D867 e-con - 00.0 - 08/2023...
  • Page 171 Check the box to activate the user Turn the check box off to deactivate the user First name Enter the first name using the touch screen keypad Last name Enter the last name using the touch screen keypad Service Instructions D867 e-con - 00.0 - 08/2023...
  • Page 172 You need to assign the new user one or several matching roles. If assigning multiple roles to the same user, you must define one role as the primary role. The primary role is highlighted with a blue font. Service Instructions D867 e-con - 00.0 - 08/2023...

  • Page 173: Smart Keys Configuration

    (3) - Button Role (2) - Bar (4) - Button Users + Role To configure the main screen for a role: 1. Press the Select role button to select the desired role. Service Instructions D867 e-con - 00.0 - 08/2023...

  • Page 174: Role Status Bar Configuration

    (3) - Button Role (2) - Bar (4) - Button Users + Role To configure the main screen for a role: 1. Press the Select role button to select the desired role. Service Instructions D867 e-con - 00.0 - 08/2023...

  • Page 175: Using Manual Data Transfer

    – and a USB key. Various options are available for the data transfer, which are explained in the subchapters. 19.7.1 Exporting data To export data: 1. Connect the USB key at the control panel. 2. Press the Export button. Service Instructions D867 e-con - 00.0 - 08/2023...
  • Page 176 • 110 ORNAMENTAL SEAM Own PDFs and videos Customer Multimedia PDFs and videos from Vendor Multimedia Dürkopp Adler  The corresponding dialog appears. For example, if you have selected Programs, perform the following steps: Service Instructions D867 e-con - 00.0 - 08/2023...
  • Page 177 4. Select the export destination. E.g.: Right USB port. Abb. 117: Exporting data (2) 5. Select a program. Fig. 118: Exporting data (3) 6. Select a folder that already exists or create a new folder. Service Instructions D867 e-con - 00.0 - 08/2023...
  • Page 178 Programming Fig. 119: Exporting data (4) 7. Confirm selection. Fig. 120: Exporting data (5)  The data is exported. Service Instructions D867 e-con - 00.0 - 08/2023...

  • Page 179: Importing Data

    Appendix ( p. 246) PDFs and videos from Vendor Multimedia Dürkopp Adler Import maintenance measures Maintenance Management  The corresponding dialog appears. For example, if you have selected Programs, perform the following steps: Service Instructions D867 e-con - 00.0 - 08/2023...
  • Page 180 Fig. 121: Importing data (1) 4. Select the import source. E.g.: Right USB port. Fig. 122: Importing data (2) 5. Select the desired folder. Fig. 123: Importing data (3) 6. Select the desired program. Service Instructions D867 e-con - 00.0 - 08/2023...
  • Page 181 Programming Abb. 124: Importing data(4) 7. Confirm selection. Fig. 125: Importing data (5)  The data is imported. The machine will be restarted if necessary. Service Instructions D867 e-con - 00.0 - 08/2023...

  • Page 182: Service

     p. 187 Settings  p. 188 Multitest  p. 192 Maintenance Management  p. 195 QONDAC  p. 196 Reset  p. 197 Network  p. 197 Logging  p. 198 Logger modules Service Instructions D867 e-con - 00.0 - 08/2023...

  • Page 183: Calibration

    Only visible if the 2-axis edge guide has been activated ( p. 150)  p. 184 Pedal  p. 185 Needle thread tension  p. 187 Teach Transmission  p. 187 Reference position Service Instructions D867 e-con - 00.0 - 08/2023...
  • Page 184 Test run must be 60 mm. 5. If the test run is not the correct length, the values must be adjusted accordingly using Fig. 126: Calibration of the Feed calibration Service Instructions D867 e-con - 00.0 - 08/2023...
  • Page 185 4. Fold the edge guide down. 5. Measure the distance between the needle and the edge guide. 6. Enter the value with the -/+ buttons. 7. Confirm the entry with Next.  The calibration is complete. Service Instructions D867 e-con - 00.0 - 08/2023...
  • Page 186 3. Press the pedal halfway back to the -1 position. 4. Press Next. 5. Release the pedal (position 0). 6. Press Next. 7. Press the pedal forward to the +1 position. 8. Press Next.  Calibration complete. 9. Press Close. Service Instructions D867 e-con - 00.0 - 08/2023...
  • Page 187 4. Call up the Service > Calibration > Needle thread tension menu. 5. Adjust the needle tension to 200 cN / 500 cN / 800 cN.  The thread tension is activated, and a tick indicator is shown (e.g. 95 ticks): Service Instructions D867 e-con - 00.0 - 08/2023...
  • Page 188 Fig. 129: Calibration of the needle thread tension 7. Change the ticks ( ) until 200 cN / 500 cN / 800 cN is indicated on the scale. 8. Save the value and exit the menu. Service Instructions D867 e-con - 00.0 - 08/2023...

  • Page 189: Settings

    Service routine chapter ( p. 14) . Icon Menu item Value range Feed dog Assemble Position to needle Feed dog movement Hook-Needle Timing Needle bar Sewing foot stroke Equal sewing foot stroke Feed Move Service Instructions D867 e-con - 00.0 - 08/2023...

  • Page 190: Multi Test

    To check the inputs: 1. Press the input.  The display switches automatically to the corresponding input in the pick list on the control panel. The status (on/off) is highlighted with a color. Service Instructions D867 e-con - 00.0 - 08/2023...
  • Page 191 1. Press the pedal.  The corresponding positions or steps are displayed in the menu. Depending on the version (analog or digital), the values are displayed directly or as a status indicator (0/1). Service Instructions D867 e-con - 00.0 - 08/2023...
  • Page 192 1. Open the menu Service > Multi test > Test Material Thickness Sensor. 2. Lift the sewing feet. 3. Place the sewing material under the sewing feet. 4. Lift the sewing feet.  The signal quality (1) must display the value 1. Service Instructions D867 e-con - 00.0 - 08/2023...
  • Page 193 Counts the skip stitches for which the sensor was unable to detect a loop Value of the skip stitch Total of skip stitches counter Pollution degree Indicates the degree of pollution. The value must be 0 on delivery. Service Instructions D867 e-con - 00.0 - 08/2023...

  • Page 194: Maintenance Management

    Logging and History, where you can view them at a later time. Fig. 132: Maintenance Management (2) ① ② (1) - Guidelines (2) - History Service Instructions D867 e-con - 00.0 - 08/2023...
  • Page 195 List of spare parts you can order which are required for the maintenance measure To create a maintenance activity: 1. Go to the Guidelines (1) section and press  A new activity with the name New Measure is created. Service Instructions D867 e-con - 00.0 - 08/2023...
  • Page 196 4. To add a description, go to the Description section, click on the icon Edit (3) and enter the text you wish to add using the touch screen keypad. 5. Add the description with a press of the button. Service Instructions D867 e-con - 00.0 - 08/2023...

  • Page 197: Qondac

    Enter the server address using Server address the touch screen keypad Information For detailed information on how to network machines, refer to the documen- tation of the QONDAC. Service Instructions D867 e-con - 00.0 - 08/2023...

  • Page 198: Reset

    Reset all data (except calibration) All parameters, programs, and calibration values are reset to the factory settings. Remove User Tutorials Remove vendor tutorials Remove log data Remove backup data Delete log files from panel and control Service Instructions D867 e-con - 00.0 - 08/2023...

  • Page 199: Network

    Control panel (1) installed control panel Levels (2) • All levels • Debug • Warning notice • Assert Data (3) • All Data • Today • Yesterday • Last two days • Last week Service Instructions D867 e-con - 00.0 - 08/2023...

  • Page 200: Logger Modules

    Menu item Store To USB Get last log files from control Get all log files from control Hardware drivers Operation panel Data configuration Startup measures Thread trimmer Sewing motor Pedal Machine process Service Instructions D867 e-con - 00.0 - 08/2023...
  • Page 201 Programming Icon Menu item Bartack Edge trimmer Stitch length Thread tension Foot lift Foot pressure Foot stroke Fabric sensor Speed manager Light barrier Function I/Os File operations Remote Service Instructions D867 e-con - 00.0 - 08/2023...

  • Page 202: Information

    The Information section allows you to set the date and time and call up information about machine components. Menu items under Information Icon Menu item Explanation Setting date and time Date and time Select time zone Copyright Service Instructions D867 e-con - 00.0 - 08/2023...
  • Page 203 Thread tension limit control statistic Operating hours Working time daily Control Control Type of the connected control Serial number Serial number of the connected control Type of the connected control Control panel panel Service Instructions D867 e-con - 00.0 - 08/2023...
  • Page 204 Programming Icon Menu item Explanation Machine Class selected class Machine subclass selected subclass Serial number Serial number of the machine Production date Production date of the machine Service Instructions D867 e-con - 00.0 - 08/2023...

  • Page 205: Performing A Software Update

    6. Select the desired update file.  The software update is performed. 7. Remove the USB key when the software update is complete.  The machine restarts and is ready for sewing. Service Instructions D867 e-con - 00.0 - 08/2023...
  • Page 206 Programming Service Instructions D867 e-con - 00.0 - 08/2023...

  • Page 207: Maintenance

    Servicing the pneumatic system (optional) Adjusting the operating pressure  Draining the water-oil mixture  Cleaning the filter element  Servicing specific components Cleaning the thread clamp  Checking the toothed belt  Service Instructions D867 e-con - 00.0 - 08/2023...

  • Page 208: Cleaning

    Use only solvent-free substances for cleaning. Fig. 136: Cleaning ④ ① ③ ② (1) - Area around the needle (3) - Area under the throat plate (2) - Hook (4) - Knife on the winder Service Instructions D867 e-con - 00.0 - 08/2023...

  • Page 209: Lubricating

    Oil is a pollutant and must not enter the sewage system or the soil. Carefully collect up used oil. Dispose of used oil and oily machine parts in accordance with national regulations. Service Instructions D867 e-con - 00.0 - 08/2023...

  • Page 210: Lubricating The Machine Head

    2. If the inspection glass lights up red, the machine is not sufficiently supplied with oil. 3. If the oil level is below the minimum level marking (3): Pour oil through the refill opening (1) but no higher than the maximum level marking (2). Service Instructions D867 e-con - 00.0 - 08/2023...

  • Page 211: Lubricating The Hook

    • Release less oil: Turn screw (1) clockwise Important The released amount of oil does not change until the operating time has run a few minutes. Sew for several minutes before you check the setting again. Service Instructions D867 e-con - 00.0 - 08/2023...

  • Page 212: Servicing The Pneumatic System (Optional)

    2. Turn the pressure regulator until the pressure gage (2) indicates the proper setting: • Increase pressure = turn clockwise • Reduce pressure = turn counterclockwise 3. Push the pressure regulator (1) down. Service Instructions D867 e-con - 00.0 - 08/2023...

  • Page 213: Draining The Water-Oil Mixture

    3. Loosen the drain screw (3) completely. 4. Allow the water-oil mixture to drain into the vessel. 5. Tighten the drain screw (3). 6. Connect the machine to the compressed air supply. Service Instructions D867 e-con - 00.0 - 08/2023...

  • Page 214: Cleaning The Filter Element

    6. Wash out the filter tray using benzine. 7. Tighten the filter element (1). 8. Tighten the collection tray (2). 9. Tighten the drain screw (3). 10. Connect the machine to the compressed air supply. Service Instructions D867 e-con - 00.0 - 08/2023...

  • Page 215: Servicing Specific Components

    4. Check the thread clamp (3) for sharp edges. If the thread clamp (3) has sharp edges: 5. Polish or change the thread clamp (3). 6. Assemble and align the thread clamp ( p. 214). Service Instructions D867 e-con - 00.0 - 08/2023...
  • Page 216 Turn the thread clamp (3) to align it.  The thread is guided straight from thread guide (7) through the thread clamp (3) to thread guide (6). 6. Tighten the threaded pin (5). Service Instructions D867 e-con - 00.0 - 08/2023...

  • Page 217: Performing The Basic Settings Of The Hook Support

    2. Slide the set collar (2) along the hook shaft (6) and onto the socket (1). 3. Push the set collar (2) up against the hook support. 4. Tighten the threaded pin (3) on the flat (5) of the hook shaft (6). Service Instructions D867 e-con - 00.0 - 08/2023...

  • Page 218: Parts List

    • Short thread trimmer ( p. 85) • Long thread trimmer ( p. 94) 20.5 Parts list A parts list can be ordered from Dürkopp Adler. Or visit our website for further information at: www.duerkopp-adler.com Service Instructions D867 e-con - 00.0 - 08/2023...

  • Page 219: Decommissioning

    5. Cover the control panel to protect it from soiling. 6. Cover the control to protect it from soiling. 7. Cover the entire machine if possible to protect it from contamination and damage. Service Instructions D867 e-con - 00.0 - 08/2023...
  • Page 220 Decommissioning Service Instructions D867 e-con - 00.0 - 08/2023...

  • Page 221: Disposal

    When disposing of the machine, be aware that it consists of a range of different materials (steel, plastic, electronic components, etc.). Follow the national regulations when disposing these materials. Service Instructions D867 e-con - 00.0 - 08/2023...
  • Page 222 Disposal Service Instructions D867 e-con - 00.0 - 08/2023...

  • Page 223: Troubleshooting

    • Check wiring in machine distributor and change it, if necessary • Measure motor phases and check for value 1005 Error Motor blocked • Check for stiff movement • Replace encoder • Replace sewing motor Service Instructions D867 e-con - 00.0 - 08/2023...
  • Page 224 Information Position not reached (during bartack) • Check the controller settings and change them if necessary (e.g. thread trimmer setting, belt tension, etc.) • Check position thread lever at top dead center Service Instructions D867 e-con - 00.0 - 08/2023...
  • Page 225 Stepper card X30 init position not • Check for stiff movement found (Stitch length) • Replace encoder • Replace motor 2176 Error Stepper card X30 not enabled • Replace the control (Stitch length) Service Instructions D867 e-con - 00.0 - 08/2023...
  • Page 226 (Foot lifting) • Check selection of class 2272 Error Stepper card X40 motor overload/ • Check selection of class overvoltage/overcurrent (Foot lifting) • Replace the control • Replace encoder • Replace stepper motor Service Instructions D867 e-con - 00.0 - 08/2023...
  • Page 227 2330 Error Stepper card X50 not responding • Perform software update • Replace the control 2331 Error Stepper card X50 initialization failure • Perform software update • Check selection of class Service Instructions D867 e-con - 00.0 - 08/2023...
  • Page 228 • Replace motor 2401 Error Stepper card X60 reference drive • Check reference sensor failure (Edge guide) 2405 Error Stepper card X60 stepper motor • Check for stiff movement blockage (Edge guide) Service Instructions D867 e-con - 00.0 - 08/2023...
  • Page 229 • Check motor phase and PE for (Edge guide) low-impedance connection • Replace encoder • Replace sewing motor 2487 Error Stepper card X60 transport interval • Perform software update failure (Edge guide) • Check selection of class Service Instructions D867 e-con - 00.0 - 08/2023...
  • Page 230 Error Stepper card X70 reference drive • Check for stiff movement failure (Upper puller) • Replace encoder • Replace motor 2583 Error Stepper card X70 overcurrent • Replace the control (Upper puller) Service Instructions D867 e-con - 00.0 - 08/2023...
  • Page 231 • Replace encoder • Replace motor 2678 Error Stepper card X80 encoder failure • Replace encoder (Bottom puller) 2679 Error Stepper card X80 Current sensor • Replace the control failure (Bottom puller) Service Instructions D867 e-con - 00.0 - 08/2023...
  • Page 232 3109 Warning Operation lock • Check tilt sensor on machine 3110 Information Right thread tension magnet is not • Check the connection of right connected thread tension magnet Service Instructions D867 e-con - 00.0 - 08/2023...
  • Page 233 • Perform software update 4201 Warning Failure SD-Card • Insert SD card • Replace the control 4430 Warning OP3000: Connection lost • Check connection to OP3000 • Replace OP3000 • Replace the control Service Instructions D867 e-con - 00.0 - 08/2023...
  • Page 234 • Switch off the control, wait until (the internal data structures are not the LEDs have gone out, and then compatible with the external data switch on the control again storage device) • Software update Service Instructions D867 e-con - 00.0 - 08/2023...
  • Page 235 • Replace motor 8127 Error Stepper Puller Top encoder failure • Connect encoder cable to the control • Use correct connection 8128 Error Stepper Puller Top Current sensor • Replace the control failure Service Instructions D867 e-con - 00.0 - 08/2023...
  • Page 236 • Perform software update encoder not initialized • Check selection of class 8174 Error Stepper Puller Bottom init position not • Check for stiff movement found • Replace encoder • Replace motor Service Instructions D867 e-con - 00.0 - 08/2023...
  • Page 237 (Edge guide) • Perform software update • Replace the control 8259 Error Stepper card initialization failure External Edge guide Y Axis (Edge guide) • Perform software update • Check selection of class Service Instructions D867 e-con - 00.0 - 08/2023...
  • Page 238 Edge guide pcb is not connected • Check cable • Perform software update • Replace PCB 9361 Error Edge guide x-axis pcb is not • Check cable connected • Perform software update • Replace PCB Service Instructions D867 e-con - 00.0 - 08/2023...
  • Page 239 Not enough thread available • Please insert a full bobbin 9930 Warning Empty bobbin • Please insert a full bobbin 9931 Information Bobbin Wind mode • Press pedal backwards exit bobbin wind mode Service Instructions D867 e-con - 00.0 - 08/2023...
  • Page 240 • Additionally on two needle machines: calibrate the left needle thread tension with parameter T 62 06 9951 Warning Please press Service stop • Please press the Service stop button to activate it Service Instructions D867 e-con - 00.0 - 08/2023...
  • Page 241 • Thread Tension too high (Warning) 9970 Warning The limit values of the thread tension • The limit values of the thread have been exceeded too often! tension have been exceeded too often! Service Instructions D867 e-con - 00.0 - 08/2023...
  • Page 242 • Poka Yoke Function 3 The system is waiting for a release of Poka Yoke Function 3. 9981 Information • Poka Yoke Function 4 The system is waiting for a release of Poka Yoke Function 4. Service Instructions D867 e-con - 00.0 - 08/2023...

  • Page 243: Errors In Sewing Process

    Throat plate, hook or Have parts reworked by qualified spread have been specialists damaged by the needle Distance from the hook Adjust the correct distance to the needle is not set ( p. 53) correctly Service Instructions D867 e-con - 00.0 - 08/2023...
  • Page 244 Needle thread and hook Check threading path thread have not been threaded correctly Needle breakage Needle thickness is Use recommended needle unsuitable for the sewing thickness material or the thread Service Instructions D867 e-con - 00.0 - 08/2023...

  • Page 245: Technical Data

    LpA = 78 dB (A); KpA = 1.04 dB (A) with • Stitch length: 6.0 mm • Sewing foot stroke: alternating: 7.0 mm • Speed: 1200 rpm • Sewing material: 2-layer Skai; 1.6 mm 900 gr/mm ; DIN 53352 Service Instructions D867 e-con - 00.0 - 08/2023...

  • Page 246: Data And Characteristic Values

    (Compressed air only required in combination with optional additional equipment) Length [mm] 1050 Width [mm] Height [mm] Weight [kg] 24.2 Requirements for fault-free operation Compressed air quality must conform to ISO 8573-1: 2010 [7:4:4]. Service Instructions D867 e-con - 00.0 - 08/2023...

  • Page 247: Appendix

    Appendix 25 Appendix 25.1 Barcode examples Fig. 145: Barcode examples (type 128) Service Instructions D867 e-con - 00.0 - 08/2023...

  • Page 248: Converting Videos For Playback On The Control Panel

    Fig. 146: Converting videos (1) To convert videos for playback on the control panel: 1. Download the HandBrake program from the website handbrake.fr and install it on your computer. Fig. 147: Converting videos (2) Service Instructions D867 e-con - 00.0 - 08/2023...
  • Page 249 Fig. 149: Converting videos (4) 6. Select the Dürkopp Adler preset file DA_WebM_Handbrake_Preset.json to import it. You can obtain the preset file from Dürkopp Adler's website or from customer service. 7. Click on Open. Service Instructions D867 e-con - 00.0 - 08/2023...
  • Page 250 9. Enter the name of the video and add the file extension .webm. 10. Click on Start Encode to start encoding. Fig. 151: Converting videos (6)  The conversion process is indicated by a progress bar. Service Instructions D867 e-con - 00.0 - 08/2023...

  • Page 251: Basic Settings Of The Machine

    Required tools: • Locking peg (included in the scope of delivery, part number 0867 104950) • Spring balance 600 gr. (part number 0APP 001503) Service Instructions D867 e-con - 00.0 - 08/2023...

  • Page 252: Wiring Diagram

    Appendix 25.4 Wiring diagram Fig. 152: Wiring diagram Service Instructions D867 e-con - 00.0 - 08/2023...
  • Page 253 Appendix Fig. 153: Wiring diagram Service Instructions D867 e-con - 00.0 - 08/2023...
  • Page 254 Appendix Fig. 154: Wiring diagram Service Instructions D867 e-con - 00.0 - 08/2023...
  • Page 255 Appendix Fig. 155: Wiring diagram Service Instructions D867 e-con - 00.0 - 08/2023...
  • Page 256 Appendix Fig. 156: Wiring diagram Service Instructions D867 e-con - 00.0 - 08/2023...
  • Page 257 Appendix Fig. 157: Wiring diagram Service Instructions D867 e-con - 00.0 - 08/2023...
  • Page 258 Appendix Fig. 158: Wiring diagram Service Instructions D867 e-con - 00.0 - 08/2023...
  • Page 259 Appendix Fig. 159: Wiring diagram Service Instructions D867 e-con - 00.0 - 08/2023...
  • Page 260 Appendix Fig. 160: Wiring diagram Service Instructions D867 e-con - 00.0 - 08/2023...
  • Page 261 Appendix Fig. 161: Wiring diagram Service Instructions D867 e-con - 00.0 - 08/2023...
  • Page 262 Appendix Fig. 162: Wiring diagram Service Instructions D867 e-con - 00.0 - 08/2023...
  • Page 263 Appendix Fig. 163: Wiring diagram " Service Instructions D867 e-con - 00.0 - 08/2023...
  • Page 264 Appendix Fig. 164: Wiring diagram Service Instructions D867 e-con - 00.0 - 08/2023...
  • Page 265 Appendix Fig. 165: Wiring diagram Service Instructions D867 e-con - 00.0 - 08/2023...
  • Page 266 Appendix Fig. 166: Wiring diagram Service Instructions D867 e-con - 00.0 - 08/2023...
  • Page 267 Appendix Fig. 167: Wiring diagram Service Instructions D867 e-con - 00.0 - 08/2023...
  • Page 268 Appendix Fig. 168: Wiring diagram Service Instructions D867 e-con - 00.0 - 08/2023...
  • Page 269 Appendix Fig. 169: Wiring diagram Service Instructions D867 e-con - 00.0 - 08/2023...
  • Page 270 Appendix Fig. 170: Wiring diagram Service Instructions D867 e-con - 00.0 - 08/2023...
  • Page 271 Appendix Fig. 171: Wiring diagram Service Instructions D867 e-con - 00.0 - 08/2023...
  • Page 272 Appendix Fig. 172: Wiring diagram Service Instructions D867 e-con - 00.0 - 08/2023...
  • Page 273 Appendix Fig. 173: Wiring diagram Service Instructions D867 e-con - 00.0 - 08/2023...
  • Page 274 Appendix Fig. 174: Wiring diagram Service Instructions D867 e-con - 00.0 - 08/2023...
  • Page 275 Appendix Fig. 175: Wiring diagram Service Instructions D867 e-con - 00.0 - 08/2023...
  • Page 276 Appendix Fig. 176: Wiring diagram Service Instructions D867 e-con - 00.0 - 08/2023...
  • Page 278 DÜRKOPP ADLER GmbH Potsdamer Str. 190 33719 Bielefeld Germany Phone: +49 (0) 521 925 00 Email: service@duerkopp-adler.com www.duerkopp-adler.com...

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