DURKOPP ADLER M-type 867 Service Instructions Manual
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DURKOPP ADLER M-type 867 Service Instructions Manual

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Summary of Contents for DURKOPP ADLER M-type 867

  • Page 1 Service instructions...
  • Page 2 All rights reserved. Property of Dürkopp Adler AG and protected by copyright. Any reuse of these contents, includ- ing extracts, is prohibited without the prior written approval of Dürkopp Adler AG. Copyright © Dürkopp Adler AG - 2015...

  • Page 3: Table Of Contents

    Table of contents About these Service Instructions..........5 Scope ................... 5 Representation conventions – symbols and characters ....5 Other documents ................6 Liability..................6 Safety information ..............7 Basic safety instructions ............... 7 Signal words and symbols used in warnings ........ 8 Working basis ................
  • Page 4 Table of contents 10.1 Setting the hook side clearance ..........44 10.2 Setting the loop stroke position ..........45 10.3 Adjusting the needle guard ............47 10.4 Setting the needle bar height............48 Setting the spool housing lifter..........50 11.1 Setting the lifting gap ..............
  • Page 5 Table of contents 20.1.2 Adjusting the slide for the needle bars ........99 20.2 Machines with moving binder ........... 100 20.3 Machines with a vertical cutter ..........101 Maintenance work ..............105 21.1 Lubrication ................105 21.1.1 Lubrication of the upper part of the machine ......106 21.1.2 Hook lubrication ................
  • Page 6 Table of contents Service Manual 867 Version 02.0 - 04/2015...

  • Page 7: About These Service Instructions

    About these Service Instructions About these Service Instructions This manual for sewing machine 867 was compiled with the utmost care. It contains information and notes in order to make long-term and reliable operation possible. 1.1 Scope This manual describes the setting and maintenance work on the 867 sewing machine.

  • Page 8: Other Documents

    About these Service Instructions Order Specifies the work to be performed before or after a setting. References  Reference to another section in the manual. Important warnings for the machine operator are specially designated. Safety Since safety is of particular importance, hazard symbols, levels of danger and their signal words are described separately in ...

  • Page 9: Safety Information

    Safety information Safety information This section contains basic information for your safety. Read the information carefully before setting up, programming, maintain- ing, or operating the machine. Make sure to follow the information included in this section. Failure to do so can result in serious injury and damage to the machine. 2.1 Basic safety instructions Only authorized personnel should use the machine.

  • Page 10: Signal Words And Symbols Used In Warnings

    Safety information in accordance with the applicable statutory provisions. Only qualified specialists may set up the machine. Anyone setting up the machine should read the operating manual first. Only qualified specialists may perform maintenance work and repairs. Anyone maintaining or setting up the machine must read the service manual first.
  • Page 11 Safety information The following symbols indicate the type of risk to personnel: Symbols Symbol Type of danger General risk Risk of electric shock Risk of puncturing Risk of crushing Examples of the layout of the warnings in the text: Examples DANGER Type and source of risk Consequences of non-observance...
  • Page 12 Safety information CAUTION Type and source of risk Consequences of non-observance Measures for avoiding the risk This is what a warning looks like for a hazard that could result in moderate or minor injury if the warn- ing is ignored. ENVIRONMENTAL PROTECTION Type and source of risk Measures for avoiding the risk...

  • Page 13: Working Basis

    Working basis Working basis 3.1 Sequence of the settings The setting positions for the sewing machine are interdependent. Observe the sequence! Always adhere to the specified sequence for the individual setting steps. Always observe all information on requirements and following settings marked at the side with ATTENTION Machine damage possible due to incorrect sequence.

  • Page 14: Removing The Covers

    Working basis 3.3 Removing the covers WARNING Risk of injury Crushing injuries from moving parts. Switch the sewing machine off before you remove the covers or refit them In many types of setting work, you will have to remove the machine covers first in order to access the components.

  • Page 15: Removing And Fitting The Arm Cover

    Working basis 3.3.2 Removing and fitting the arm cover Fig. 2: Removing and fitting the arm cover ① ② ③ (1) - Screws (3) - Arm cover (2) - Left adjusting wheel for presser foot stroke Removing the arm cover 1.

  • Page 16: Removing And Fitting The Valve Cover

    Working basis Removing the head cover 1. Loosen the screws (1). 2. Remove the head cover (2). Fitting the head cover 1. Fit the head cover (2). 2. Tighten the screws (1). 3.3.4 Removing and fitting the valve cover Fig. 4: Removing and fitting the valve cover ①...

  • Page 17: Opening And Closing The Throat Plate Slide

    Working basis 3.3.5 Opening and closing the throat plate slide Fig. 5: Opening and closing the throat plate slide ① ② ③ (1) - Throat plate slide (3) - Clamping spring (2) - Throat plate Opening the throat plate slide 1.

  • Page 18: Removing And Installing The Feed-Dog

    Working basis Fig. 6: Removing and installing the throat plate ① ④ ② ③ (1) - Screws (3) - Nose (2) - Throat plate (4) - Bobbin housing Removing the throat plate 1. Open the throat plate slide ( page15). 2.
  • Page 19 Working basis Fig. 7: Removing and installing the feed-dog (1) - Feed-dog (3) - Screws (2) - Feed-dog carrier Removing the feed-dog 1. Remove the throat plate ( page15). 2. Loosen the screws (3). 3. Take the feed-dog (1) off the feed-dog carrier (2). Installing the feed-dog 1.

  • Page 20: Surfaces On Shafts

    Working basis 3.4 Surfaces on shafts Screwing onto Fig. 8: Surfaces on shafts the surface (1) - Surface (2) - Shaft Some shafts have flat surfaces at those points where the components are screwed on. This strengthens the connection and setting work is made easier.

  • Page 21: Putting The Handwheel Into Position

    Working basis Fig. 10: Locking the sewing machine in place ① ③ ② (1) - Groove (3) - Locking peg (2) - Locking opening Locking the machine in place 1. Remove the plug from the locking opening (2). 2. Turn the handwheel until the appropriate groove (1) is in front of the locking opening (2): •...
  • Page 22 Working basis Service Manual 867 Version 02.0 - 04/2015...

  • Page 23: Setting The Handwheel Scale

    Setting the handwheel scale Setting the handwheel scale WARNING Risk of injury Crushing injuries from moving parts. Switch the sewing machine off before you check and set the position of the handwheel on the arm shaft. Checking the correct setting 1.

  • Page 24: Positioning The Arm Shaft

    Positioning the arm shaft Positioning the arm shaft WARNING Risk of injury Crushing injuries from moving parts. Switch the sewing machine off before you check and set the position of the arm shaft crank. Proper setting The three setscrews (3) on the arm shaft crank (1) are seated completely on the surface.

  • Page 25: Positioning The Toothed Belt Wheels

    Positioning the toothed belt wheels Positioning the toothed belt wheels The two toothed belt wheels must be positioned one on top of the other such that the toothed belt can run correctly. In machines with normal lengths, the winder wheel is directly next to the upper toothed belt wheel and determines its alignment.
  • Page 26 Positioning the toothed belt wheels Fig. 14: Setting the upper toothed belt wheel (1) - Upper toothed belt wheel (4) - Toothed belt (2) - Setscrews (5) - Surface of arm shaft (3) - Winder wheel (position in machines with normal lengths) Setting steps 1.

  • Page 27: Lower Toothed Belt Wheel

    Positioning the toothed belt wheels 6.2 Lower toothed belt wheel WARNING Risk of injury Crushing injuries from moving parts. Switch the sewing machine off before you check and set the lower toothed belt wheel. Proper setting The two setscrews for the lower toothed belt wheel are seated completely on the surface of the lower shaft.

  • Page 28: Setting The Stitch Length Adjusting Wheels

    Setting the stitch length adjusting wheels Setting the stitch length adjusting wheels Fig. 16: Stitch length adjusting wheels +/– +/– (1) - Keypad key for the stitch length (2) - Upper stitch length adjusting wheel on the machine arm (3) - Lower stitch length adjusting wheel The two adjusting wheels on the machine column determine the stitch length.

  • Page 29: Setting The Upper Stitch Length Adjusting Wheel

    Setting the stitch length adjusting wheels 7.1 Setting the upper stitch length adjusting wheel WARNING Risk of injury Crushing injuries from moving parts. Switch the sewing machine off before you set the upper stitch length adjusting wheel. Proper setting Upper stitch length adjusting wheel to 0: ...
  • Page 30 Setting the stitch length adjusting wheels 5. Carefully turn the shaft (5) clockwise using a 10 mm wrench. Fig. 18: Setting the upper stitch length adjusting wheel II ⑧ ⑨ ⑩ ⑪ ⑫ (8) - Frame for the stitch regulator gear (11) - Tension spring (9) - Plates for the stitch regulator gear (12) - Screw...

  • Page 31: Setting The Lower Stitch Length Adjusting Wheel

    Setting the stitch length adjusting wheels 7.2 Setting the lower stitch length adjusting wheel WARNING Risk of injury The lower stitch length adjusting wheel has to be set when the machine is switched on, because a switchover is automatically made to the upper adjusting wheel when the machine is switched off.

  • Page 32: Setting The Stitch Length Limit

    Setting the stitch length adjusting wheels Fig. 20: Setting the lower stitch length adjusting wheel II ⑦ ① ⑥ ② ③ ⑤ ④ (1) - Upper stitch length adjusting wheel (5) - Shaft (2) - Screw (6) - Scale (3) - Lower stitch length adjusting wheel (7) - Key (4) - Adjusting mark 3.
  • Page 33 Setting the stitch length adjusting wheels WARNING Risk of injury Crushing injuries from moving parts. Switch off the sewing machine before setting the maximum stitch length limit. 12, 9, or 6 mm can be selected as the maximum stitch length. In doing so, the appropriate throat plate has to be selected for the respective maximum stitch length.

  • Page 34: Setting The Eccentric For The Forward And Backward Stitches

    Setting the stitch length adjusting wheels 5. Remove the setscrew from one of the three mark-off openings (3). 6. Screw the setscrew into the mark-off opening for the required maximum stitch length. The openings are given numbers for the stitch length: 7.
  • Page 35 Setting the stitch length adjusting wheels The slot in the eccentric screw (3) is parallel to the setscrew (2), the recess (4) faces the front. If the forward and backward stitches are not the same length: • Turning clockwise: The forward stitch becomes larger, the backward stitch smaller. •...

  • Page 36: Setting The Feed-Dog

    Setting the feed-dog Setting the feed-dog The position and the movement of the feed-dog and needle bar have to be coordinated such that the needle pierces exactly in the center of the nee- dle hole of the feed-dog. Order First check the following setting: •...

  • Page 37: Moving The Feed-Dog

    Setting the feed-dog 8.1.1 Moving the feed-dog Cover • Throat plate ( 3.3.6 Removing and installing the throat plate, page 15) Fig. 23: Moving the feed-dog on the feed-dog carrier (1) - Feed-dog (3) - Screws (2) - Feed-dog carrier Setting steps 1.

  • Page 38: Moving The Feed-Dog Carrier

    Setting the feed-dog 8.1.2 Moving the feed-dog carrier The feed-dog carrier is connected to the stitch regulator gear via the slid- ing shaft and can be moved on this shaft. Cover • Tilt the upper section ( 3.3.1 Access to the machine bottom section, page 12) Fig.

  • Page 39: Setting The Feed-Dog Movement

    Setting the feed-dog 8.2 Setting the feed-dog movement The feed-dog moves in an elliptical cycle. To align this correctly, both the feed movement and the stroke height and stroke movement of the feed-dog have to be set. Order First check the following setting: •...

  • Page 40: Setting The Feed-Dog Height In The Top Dead Center

    Setting the feed-dog and needle in the process. 5. Turn the pusher eccentric (2) such that the feed-dog and needle no longer move when the stitch adjustment lever (3) is pressed. 6. Tighten the setscrews (1). 8.2.2 Setting the feed-dog height in the top dead center WARNING Risk of injury Crushing injuries from moving parts.

  • Page 41: Setting The Stroke Movement

    Setting the feed-dog 8.2.3 Setting the stroke movement WARNING Risk of injury Crushing injuries from moving parts. Switch the sewing machine off before you check and set the stroke movement of the feed-dog. Order First check the following setting: • Feed-dog height ( 8.2.2 Setting the feed-dog height in the top dead center, page 38) Proper setting At the front dead center (handwheel position 90°) and at the rear dead...

  • Page 42: Setting The Compensating Weight

    Setting the feed-dog 8.2.4 Setting the compensating weight WARNING Risk of injury Crushing injuries from moving parts. Switch the sewing machine off before you check and set the position of the compensating weight. Proper setting Handwheel position 210°:  The setscrew for the compensating weight is parallel to the base plate. Cover •...

  • Page 43: Aligning The Needle Bar Linkage

    Aligning the needle bar linkage Aligning the needle bar linkage Order First check the following setting: • A straight and undamaged needle has to be inserted ( Operating manual Section, Inserting and replacing the needle) Proper setting Position the upper and lower stitch length adjusting wheel to 0. ...

  • Page 44: Aligning The Needle Bar Linkage In The Sewing Direction

    Aligning the needle bar linkage Fig. 30: Aligning the thread lever sideways (5) - Arm shaft crank (7) - Thread lever (6) - Setscrews 3. Release both setscrews (6) on the arm shaft crank (5). Make sure that the setscrews stay on the surface. 4.
  • Page 45 Aligning the needle bar linkage Fig. 31: Aligning the needle bar linkage in the sewing direction ① ② ⑤ ③ ④ (1) - Arm surface (4) - Setscrews (2) - Center of bolt (5) - Screw (3) - Lever Proper setting Upper stitch length adjusting wheel to 0: ...

  • Page 46: Position Of The Hook And Needle

    Position of the hook and needle 10 Position of the hook and needle 10.1 Setting the hook side clearance WARNING Risk of injury Crushing injuries from moving parts. Switch off the sewing machine before checking and setting the hook side clearance. Order First check the following settings: •...

  • Page 47: Setting The Loop Stroke Position

    Position of the hook and needle Fig. 32: Setting the hook clearance (1) - Clamping ring (4) - Screws (2) - Setscrews (5) - Needle groove (3) - Hook support (6) - Hook tip 1. Machine locked in place at position 1 ( page 18). 2.
  • Page 48 Position of the hook and needle Fig. 33: Loop stroke position – position of the hook tip (1) - Vertical center line of the needle (2) - Hook tip The loop stroke is precisely 2 mm. Order First check the following settings: •...

  • Page 49: Adjusting The Needle Guard

    Position of the hook and needle Setting steps 1. Lock the machine in place at position 1 ( page 18). 2. Position the upper stitch length adjusting wheel to 0. 3. Loosen all four setscrews (2) for the hook clamping ring (1). 4.

  • Page 50: Setting The Needle Bar Height

    Position of the hook and needle Proper setting Machine locked in place at position 1 ( page 18).  The needle guard pushes the needle just enough away so that it can- not be touched by the hook tip. Cover •...
  • Page 51 Position of the hook and needle • A straight and undamaged needle has to be inserted ( Operating manual Section, Inserting and replacing the needle) Proper setting Machine locked in place in position 1 ( page 18) and upper stitch length adjusting wheel set to 0.

  • Page 52: Setting The Spool Housing Lifter

    Setting the spool housing lifter 11 Setting the spool housing lifter Fig. 37: Spool housing lifter (1) - Bobbin housing (3) - Spool housing nose (2) - Spool housing lifter (4) - Recess in the throat plate The hook pulls the needle thread through between the nose of the spool housing (3) and the recess in the throat plate (4).

  • Page 53: Setting The Point In Time Of Opening

    Setting the spool housing lifter Cover • Tilt the upper section ( 3.3.1 Access to the machine bottom section, page 12) • Throat plate slide ( 3.3.5 Opening and closing the throat plate slide, page 15) Fig. 38: Setting the lifting gap (1) - Setscrew (3) - Screw (2) - Cover...
  • Page 54 Setting the spool housing lifter approx. 100°. In 2-needle machines, this happens when the handwheel position is approx. 100° for the right-hand hook, and when the handwheel position is approx. 300° for the left-hand hook. For 100° or 300°, the control cam setscrew (4) is exactly in the middle of the opening.

  • Page 55: Sewing Feet

    Sewing feet 12 Sewing feet The two adjusting wheels (3) on the machine arm determine how high the presser foot (1) and feeding foot (2) are raised during the sewing process. The left adjusting wheel determines the normal sewing foot stroke. The right adjusting wheel determines the elevated sewing foot stroke.

  • Page 56: Setting The Stroke Movement For The Feeding Foot

    Sewing feet Fig. 41: Setting an even sewing foot stroke (1) - Presser foot (3) - Screw (2) - Feeding foot (4) - Sewing foot lever Performing the setting steps 1. Set the handwheel to the 0° position. 2. Loosen the screw (3). 3.
  • Page 57 Sewing feet Proper setting Left adjusting wheel for the sewing foot stroke set to 9 and the upper stitch length adjusting wheel to 0.  The feeding foot (1) touches down exactly on the feed-dog (2) when the downwards movement of the needle tip (3) reaches the upper edge of the feeding foot.

  • Page 58: Setting Presser Foot Pressure

    Sewing feet 6. Unscrew the setscrew (3) far enough so that there is no longer any contact with the clamp. 12.3 Setting presser foot pressure The adjusting wheel at the top left of the machine arm determines the pressure for the sewing feet on the material to be sewn. The pressure can be adjusted continuously by turning the adjusting wheel.

  • Page 59: Setting The Sewing Foot Lifting Height

    Sewing feet 12.4 Setting the sewing foot lifting height WARNING Risk of injury The sewing machine must remain switched on so that the sewing feet can be raised. Work very carefully when you check and set the lift- ing height for the sewing feet. Do not put your hands under the sewing feet when they are being lowered.

  • Page 60: Setting Needle Thread Tension

    Setting needle thread tension 13 Setting needle thread tension 13.1 Setting the thread regulator WARNING Risk of injury Risk of crushing injuries and stab wounds from mov- ing and sharp parts. Switch off the sewing machine before checking and setting the thread regulator. The thread regulator determines the tension applied to guide the needle thread around the hook.

  • Page 61: Setting The Thread Tensioning Spring

    Setting needle thread tension 2. Loosen the screw (2). 3. Move the thread regulator • To reduce tension: Push to the left • To increase tension: Push to the right 4. Tighten the screw (2). 13.2 Setting the thread tensioning spring WARNING Risk of injury Risk of crushing injuries and stab wounds from mov-...
  • Page 62 Setting needle thread tension 3. Setting the spring tension: Turn the tension disc (3): • Greater spring tension: Turn to the left: • Less spring tension: Turn to the right: Do not twist the stop collar in doing so. 4. Tighten the screw (4). Service Manual 867 Version 02.0 - 04/2015...

  • Page 63: Winder

    Winder 14 Winder 14.1 Position of the winder wheel in long arm machines Long arm machines have the winder in the center of the machine arm. The Long arm machines winder wheel is therefore not aligned on the upper toothed belt wheel in long arm machines, but rather on the driver wheel in the machine arm.

  • Page 64: Setting The Winder

    Winder 14.2 Setting the winder WARNING Risk of injury Crushing injuries from moving parts. Switch off the sewing machine before setting the winder. Proper setting The winder wheel runs smoothly and without axial play. The winding process will stop automatically when the required filling quan- tity of the bobbin is reached.
  • Page 65 Winder 5. Fold the winder lever (3) upwards as far as it will go to the thread. Fig. 50: Setting the winder run and automatic stop (5) - Clamp (8) - Setscrew (6) - Winder wheel (9) - Switch cam (7) - Setscrew (10) - Leaf spring Setting the winder run...

  • Page 66: Setting The Hook Thread Guide

    Winder bobbin is 2 – 3 mm. 13.Set the clamp (5) such that it is resting against the locking disc (14). 14.Set the clamp (5) such that its distance to the winder wheel (6) is 0.5 mm. 15.Tighten the setscrew in the clamp (5). Fig.
  • Page 67 Winder 2. Turn the hook thread guide (2): • To the front: The thread will be wound on further to the front • To the rear: The thread will be wound on further to the rear Service Manual 867 Version 02.0 - 04/2015...

  • Page 68: Thread Cutter

    Thread cutter 15 Thread cutter 15.1 Setting the height of the thread-pulling knife WARNING Risk of injury Risk of crushing injuries and stab wounds from mov- ing and sharp parts. Switch the sewing machine off before you check and set the height of the thread-pulling knife. The height of the thread-pulling knife is factory-set such that the distance (5) between the upper edge of the knife carrier (4) and the hook bearing screw-on surface (3) is 10.7+0.05 mm.

  • Page 69: Setting The Cutoff Curve

    Thread cutter 4. Non-required washers on the top side between the thread-pulling knife (2) and screw (6) should be kept. 5. Screw down the thread-pulling knife (2) using screw (6). 15.2 Setting the cutoff curve WARNING Risk of injury Risk of crushing injuries and stab wounds from mov- ing and sharp parts.
  • Page 70 Thread cutter Screw the four setscrews (2) tightly in place on the clamping ring (1) before you loosen the setscrews (5). The clamping ring (1) and control cam (4) are both mutually used as a stop and should not be undone at the same time.

  • Page 71: Setting The Cutting Pressure

    Thread cutter 15.3 Setting the cutting pressure WARNING Risk of injury Risk of crushing injuries and stab wounds from mov- ing and sharp parts. Switch the sewing machine off before you check and set the counter-blade and the hook thread clamp.

  • Page 72: Adjusting The Needle Thread Tension

    Thread cutter 3. Position the thread-pulling knife (3) such that the arrow mark is exactly next to the tip of the counter-blade (2). 4. Turn the hook thread clamp (5) such that it rests against the thread- pulling knife (3). 5.
  • Page 73 Thread cutter Fig. 58: Setting point in time for cutting (1) - Roller (4) - Setscrews (2) - Clamping ring (5) - Counter-blade (3) - Control cam (6) - Thread-pulling knife Setting steps 1. Loosen the setscrews (4). 2. Turn the handwheel until the thread-pulling knife (6) can be swung out by hand.
  • Page 74 Thread cutter Service Manual 867 Version 02.0 - 04/2015...

  • Page 75: Short Thread Cutter (Kfa)

    Short thread cutter (KFA) 16 Short thread cutter (KFA) Important Correct setup of the short thread cutter requires that the necessary work steps be performed in the order given in this chapter. 16.1 General information videos of KFA settings, visit our YouTube channel. Fig.
  • Page 76 Short thread cutter (KFA) The height of the thread-pulling knife is determined by the height of the counter-blade. The upper edges of the two knives must be on the same level. Thread-pulling knife position The thread-pulling knife (1) cannot be moved on the knife carrier (3). Therefore, the cutting pressure does not have to be set after replacing the thread-pulling knife (1).

  • Page 77: Setting The Locking Latch

    Short thread cutter (KFA) 16.2 Setting the locking latch NOTICE Risk of breakage Never operate the machine without the thread-pulling knife. The reverse-motion lock for the bobbin housing is on the thread- pulling knife. Fig. 61: Setting the locking latch ①...

  • Page 78: Setting The Thread-Pulling Knife

    Short thread cutter (KFA) 16.3 Setting the thread-pulling knife WARNING Risk of injury! Risk of crushing injuries and stab wounds from sharp and moving parts. Switch the sewing machine off before you check and set the thread-pulling knife. NOTICE Risk of breakage Never operate the machine without the thread-pulling knife.
  • Page 79 Short thread cutter (KFA) Setting steps 1. Loosen all 4 screws on the clamping ring (6) and push the clamping ring (6) toward the hook bearing. 2. Tighten all 4 screws on the clamping ring (6). 3. Loosen both setscrews on the control cam (7). 4.

  • Page 80: Setting The Counter-Blade

    Short thread cutter (KFA) 16.4 Setting the counter-blade WARNING Risk of injury! Risk of crushing injuries and stab wounds from sharp and moving parts. Switch the sewing machine off before you check and set the counter-blade. Fig. 63: Setting the counter-blade ①...
  • Page 81 Short thread cutter (KFA) Cover Throat plate slide ( 3.3.5 Opening and closing the throat plate slide, S. 15) Setting the cutting pressure The shape of the thread-pulling knife automatically creates the required cutting pressure as soon as both cutting edges are on top of one another. Fig.

  • Page 82: Setting The Cutoff Position

    Short thread cutter (KFA) 16.5 Setting the cutoff position WARNING Risk of injury! Risk of crushing injuries and stab wounds from sharp and moving parts. Switch the sewing unit off before checking and setting the cutoff position. Fig. 65: Setting the cutoff position ①...
  • Page 83 Short thread cutter (KFA) Setting steps 1. Loosen the setscrews (6) on the control cam (5). 2. Move the control cam (5) towards the clamping ring (4) until it makes contact and correct the position of the control cam (5). 3.
  • Page 84 Short thread cutter (KFA) Service Manual 867 Version 02.0 - 04/2015...

  • Page 85: Setting The Potentiometer

    Setting the potentiometer 17 Setting the potentiometer WARNING Increased risk of injury The machine remains switched on when the poten- tiometer is set. Carry out all work with extreme caution. The potentiometer adjusts the number of stitches to the set sewing foot stroke and reduces the number of stitches if the sewing foot stroke is too much.
  • Page 86 Setting the potentiometer Fig. 67: Setting the potentiometer (1) - Setscrews (3) - Setscrew for the setting shaft (2) - Connecting clamp for lifting cylinder (4) - Potentiometer 6. Check whether the lifting gear plates are flush. If the plates are not flush: 7.

  • Page 87: Setting The Safety Snap-On Coupling

    Setting the safety snap-on coupling 18 Setting the safety snap-on coupling The safety snap-on coupling disengages in the event of the thread jam- ming and thus prevents the hook from being misadjusted or damaged. 18.1 Attaching the safety snap-on coupling WARNING Risk of injury Crushing injuries from moving parts.

  • Page 88: Setting The Torque

    Setting the safety snap-on coupling 18.2 Setting the torque WARNING Risk of injury Crushing injuries from moving parts. Switch off the sewing machine before checking and setting the safety snap-on coupling. ATTENTION Machine damage due to incorrect torque If you change the torque, it could be that the coupling will not disengage although this would be required.

  • Page 89: Machines With Integrated Motor

    Machines with integrated motor 19 Machines with integrated motor DANGER Risk of injury from electricity. Unprotected contact with electricity can result in serious injuries or death. Work on the electrical system must ONLY be per- formed by qualified electricians or appropriately trained and authorized personnel.

  • Page 90: Disassembling The Drive

    Machines with integrated motor 19.2 Disassembling the drive Removing the Fig. 71: Removing the handwheel and handwheel flange handwheel and handwheel flange ④ ① ② ③ (1) - Handwheel (3) - Setscrews (2) - Screws (4) - Handwheel flange 1. Undo all three screws (2) on the handwheel (1). 2.
  • Page 91 Machines with integrated motor Removing Fig. 73: Removing the encoder the encoder ① ② ③ ④ ⑤ (1) - Encoder disc (4) - Encoder plug (2) - Encoder (5) - Plugs L1, L2, L3 (3) - Retaining plate 1. Disconnect plugs L1, L2, and L3 (5). 2.
  • Page 92 Machines with integrated motor Removing Fig. 74: Removing the stator the stator ① ③ ② (1) - Screws (3) - Stator with ring (2) - Cover plate 1. Undo all three screws (1). 2. Remove the cover plate (2). 3. Remove the stator with ring (3). Removing Fig.

  • Page 93: Assembling The Drive

    Machines with integrated motor 19.3 Assembling the drive Attaching Fig. 76: Attaching the rotor ① ② ③ the rotor (1) - Threaded screw (3) - Rotor with deep groove ball bearing (2) - Threaded screw 1. Push the rotor (3) onto the shaft until the deep groove ball bearing is resting against the stop.
  • Page 94 Machines with integrated motor Attaching the stator CAUTION Magnetism! Work carefully and in a controlled manner, since the stator can be pulled out of your hands. Fig. 77: Attaching the stator ① ③ ② (1) - Screws (3) - Stator with ring (2) - Cover plate 1.
  • Page 95 Machines with integrated motor Attaching Fig. 78: Attaching the encoder ① the encoder ② ③ ④ ⑤ (1) - Encoder disc (4) - Encoder plug (2) - Encoder (5) - Plugs L1, L2, L3 (3) - Retaining plate 1. Push the encoder (2) and encoder disc (1) onto the shaft. 2.
  • Page 96 Machines with integrated motor Attaching Fig. 79: Attaching the cover the cover ① ② ③ ④ ⑤ (1) - Screws (4) - Screws (2) - Upper cover (5) - Lower cover (3) - Dial (depending on machine) 1. Carefully attach the upper cover (2) from the side, paying attention to the dial (3) in doing so.
  • Page 97 Machines with integrated motor Attaching Fig. 81: Attaching the handwheel flange the handwheel flange ④ ① ② ③ (1) - Handwheel flange (3) - Marking for handwheel flange (2) - Cover marking (4) - Setscrews 1. Attach the handwheel flange (1) such that the two markings (2, 3) are in line.

  • Page 98: Replacing The Fuse

    Machines with integrated motor 19.4 Replacing the fuse The fuse is for the built-in sewing lamp transformer. Fig. 83: Replacing the fuse ① (1) - Fuse 1. Replace the fuse. Value: 0.63 A T. 19.5 Replacing the PCB Fig. 84: Replacing the PCB ①...

  • Page 99: Special Machines

    Special machines 20 Special machines 20.1 Machines with switchable needle bars: 20.1.1 Setting the needle bar height WARNING Risk of injury Risk of crushing injuries and stab wounds from mov- ing and sharp parts. Switch off the sewing machine before checking and setting the needle bar height.
  • Page 100 Special machines Fig. 86: Needle bar height for machines with switchable needle bars II ⑤ ② ④ ③ ⑥ (2) - Setscrew (5) - Hexagonal pin (3) - Needle bar (6) - Setscrew (4) - Needle clamp Setting steps 1. Set stitch length adjusting wheel to 0. 2.

  • Page 101: Adjusting The Slide For The Needle Bars

    Special machines 20.1.2 Adjusting the slide for the needle bars WARNING Risk of injury Risk of crushing injuries and stab wounds from mov- ing and sharp parts. Switch off the sewing machine before adjusting the slide. Proper setting The position of the slide (1) must be adjusted such that the center of the pin (4) of the slide (1) is exactly on the peg (3) when the slide is in zero position (both needles switched on).

  • Page 102: Machines With Moving Binder

    Special machines 20.2 Machines with moving binder Sewing machines with a moving binder allow the edge of the sewing mate- rial to be bound simultaneously. WARNING Risk of injury Risk of crushing injuries and stab wounds from mov- ing and sharp parts. Switch off the sewing machine before setting the binder.

  • Page 103: Machines With A Vertical Cutter

    Special machines Fine adjustment of synchronous operation 4. Loosen the screw (6). 5. Remove the lever (4). 6. Adjust the clamp (5) on the shaft (2). The clamp can be adjusted to the right or left as well as up or down. 20.3 Machines with a vertical cutter Sewing machines with a vertical cutter allow the sewing material to be cut during the sewing process.
  • Page 104 Special machines 3. Tighten the screws (2). Adjusting the cutter stroke Fig. 90: Adjusting the vertical cutter II ① ② ③ ④ (1) - Cutter (3) - Nut (2) - Cover (4) - Screw The stroke height of the cutter (1) can be set. This is necessary if the cutter was reground and is now shorter.
  • Page 105 Special machines Correcting cutter overlap Fig. 91: Adjusting the vertical cutter III ① ② ③ (1) - Screw (3) - Counter-blade (2) - Cutter If the cutter (2) is at the lower dead center, the overlap should be 0.5 mm. Setting steps 1.
  • Page 106 Special machines Service Manual 867 Version 02.0 - 04/2015...

  • Page 107: Maintenance Work

    Maintenance work 21 Maintenance work 21.1 Lubrication WARNING Risk of injuries due to contact with oil. Contact with oil can cause irritation, rashes, aller- gies or skin injuries. ALWAYS avoid long-term contact with oil. ALWAYS thoroughly wash the affected areas if con- tact with oil occurs.

  • Page 108: Lubrication Of The Upper Part Of The Machine

    Maintenance work 21.1.1 Lubrication of the upper part of the machine The central oil lubrication system supplies all bearing positions automati- cally with oil from the reservoir. ATTENTION Machine damage due to incorrect oil level Too little or too much oil can result in damages to the machine. Check the oil level every day and top up the oil, if necessary.

  • Page 109: Hook Lubrication

    Maintenance work 21.1.2 Hook lubrication WARNING Risk of injury Risk of crushing injuries and stab wounds from mov- ing and sharp parts. When holding the blotting paper, make sure that you do not reach into the hook or underneath the area of the needle and sewing feet.

  • Page 110: Pneumatic System

    Maintenance work 21.2 Pneumatic system 21.2.1 Setting operating pressure Proper setting The operating pressure is 6 bar. Check the pressure on the pressure indicator every day. The pressure cannot deviate by more than 1 bar. ATTENTION Machine damage due to incorrect pressure Incorrect pressure can result in damage to the machine.

  • Page 111: Draining The Water Condensation

    Maintenance work 21.2.2 Draining the water condensation Water condensation may accumulate in the water separator of the pres- sure controller. Proper setting Water condensation cannot rise up to the filter element (1). Check the water level in the water separator on a daily basis. WARNING Risk of injury Switch off the machine at the main power switch...

  • Page 112: Cleaning The Filter Element

    Maintenance work 21.2.3 Cleaning the filter element WARNING Risk of injury Switch off the machine at the main power switch and disconnect it from the pneumatic network before you clean the filter element. ATTENTION Damage to the paintwork due to solvent-based cleaners. Solvent-based cleaners damage the filter.

  • Page 113: Cleaning Work

    Maintenance work 21.3 Cleaning work 21.3.1 Cleaning the machine Lint and thread remnants should be removed after every eight hours of operation using a compressed-air pistol or a brush. In the case of very fluffy material to be sewn, the machine must be cleaned more frequently. WARNING Risk of injury Switch off the machine at the main power switch...

  • Page 114: Clean The Motor Fan Sieve

    Maintenance work 21.3.2 Clean the motor fan sieve The motor fan sieve must be cleaned once a month using a compressed- air pistol. When very fluffy material is used for sewing, the motor fan sieve must be cleaned more frequently. WARNING Risk of injury Switch off the machine at the main power switch...
  • Page 116 DÜRKOPP ADLER AG Potsdamer Str. 190 33719 Bielefeld Germany Phone +49 (0) 521 925 00 E-Mail: service@duerkopp-adler.com www.duerkopp-adler.com...

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