DURKOPP ADLER 867 Service Instructions Manual
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DURKOPP ADLER 867 Service Instructions Manual

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Summary of Contents for DURKOPP ADLER 867

  • Page 1 Service Instructions...
  • Page 2 IMPORTANT READ CAREFULLY BEFORE USE KEEP FOR FUTURE REFERENCE All rights reserved. Property of Dürkopp Adler AG and protected by copyright. Any reuse of these contents, including extracts, is prohibited without the prior written approval of Dürkopp Adler AG. Copyright © Dürkopp Adler AG 2019...

  • Page 3: Table Of Contents

    8.3.2 Adjusting the compensating weight ..........41 Feed dog lift (adjustable stroke eccentric) ........42 8.4.1 Adjusting the stroke movement ..........42 8.4.2 Adjusting the stroke eccentric............. 43 Aligning the needle bar linkage..........45 Service Instructions 867 - 04.0 - 10/2019...
  • Page 4 Adjusting the torque..............86 Machines with integrated motor..........87 19.1 Overview of the components ............87 19.2 Disassembling the drive ............. 88 19.2.1 Disassembling the handwheel and handwheel flange....88 19.2.2 Disassembling the cover ............89 Service Instructions 867 - 04.0 - 10/2019...
  • Page 5 Disposal................... 127 Troubleshooting ..............129 25.1 Customer Service ..............129 25.2 Messages of the software............129 25.2.1 Information messages .............. 129 25.2.2 Error Messages ................ 132 25.3 Errors in sewing process ............135 Service Instructions 867 - 04.0 - 10/2019...
  • Page 6 Table of Contents Technical data................. 137 26.1 Noise emission ................. 137 26.2 Data overview by subclasses ........... 138 26.3 Permissible maximum speeds ..........147 26.4 Requirements for fault-free operation ........152 Appendix ................. 153 Service Instructions 867 - 04.0 - 10/2019...

  • Page 7: About These Instructions

    Steps to be performed for service, maintenance, and installation Steps to be performed via the software control panel The individual steps are numbered: First step Second step The steps must always be followed in the specified order. … Service Instructions 867 - 04.0 - 10/2019...

  • Page 8: 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 867 - 04.0 - 10/2019...

  • Page 9: 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 867 - 04.0 - 10/2019...
  • Page 10 About these instructions Service Instructions 867 - 04.0 - 10/2019...

  • Page 11: Safety

    • Set up the machine/put 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 867 - 04.0 - 10/2019...

  • 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 Symbol Type of danger General Electric shock Service Instructions 867 - 04.0 - 10/2019...
  • Page 13 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 moderate or minor injury if the warning is ignored. Service Instructions 867 - 04.0 - 10/2019...
  • Page 14 NOTICE 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 867 - 04.0 - 10/2019...

  • Page 15: Working Basis

    1. Lay any excess cabling neatly in proper cable snakes. 2. Bind together the cable loops with cable ties. Important Tie loops wherever possible to fixed parts. The cables must be secured firmly. 3. Cut off any overlapping cable ties. Service Instructions 867 - 04.0 - 10/2019...

  • Page 16: Removing The Covers

    Tilting the machine head To tilt the machine head: 1. Tilt the machine head as far as it will go. Erecting the machine head To erect the machine head: 1. Erect the machine head. Service Instructions 867 - 04.0 - 10/2019...

  • Page 17: Assembling And Disassembling The Arm Cover

    Assembling the arm cover To assemble the arm cover: 1. Position the left adjusting wheel for the sewing foot stroke (2) to 2. 2. Assemble the arm cover (3). 3. Tighten the screws (1). Service Instructions 867 - 04.0 - 10/2019...

  • Page 18: Assembling And Disassembling The Head Cover

    To disassemble the head cover: 1. Loosen the screws (1). 2. Disassemble the head cover (2). Assemble the head cover To assemble the head cover: 1. Assemble the head cover (2). 2. Tighten the screws (1). Service Instructions 867 - 04.0 - 10/2019...

  • Page 19: Assembling And Disassembling The Valve Cover

    Make sure not to tear off any cables. Assembling the valve cover To assemble the valve cover: 1. Assemble the valve cover (2). 2. Tighten the screws (1). Important Make sure not to pinch any cables. Service Instructions 867 - 04.0 - 10/2019...

  • Page 20: Opening And Closing The Throat Plate Slides

    1. Press the clamping spring (3) downwards. 2. Push the throat plate slides (1) apart. Closing the throat plate slides To close the throat plate slides: 1. Push the throat plate slides (1) up to the throat plate (2). Service Instructions 867 - 04.0 - 10/2019...

  • Page 21: Assembling And Disassembling The Throat Plate

    1. Insert the throat plate (2). Ensure that the nose of the bobbin case (3) is in the cutout of the throat plate. 2. Tighten the screws (1). 3. Close the throat plate slides ( p. 18). Service Instructions 867 - 04.0 - 10/2019...

  • Page 22: Assembling And Disassembling The Feed Dog

    Check the feed dog position in its movement at maximum stitch length (depending on the equipment: 6, 9 or 12) by turning the handwheel. The feed dog must not hit against the throat plate. Service Instructions 867 - 04.0 - 10/2019...

  • Page 23: Flats On Shafts

    For all adjustments on the surface, the first screw in the direction of rota- tion is screwed onto the surface. Important Always ensure that the screw faces are completely flush with the surface. Service Instructions 867 - 04.0 - 10/2019...

  • Page 24: Locking The Machine In Place

    • Adjusting the loop stroke and needle bar height • Position 2: Handwheel zero position • 3 mm end in the small slot • Adjusting the handwheel position and checking the top dead center for the needle bar Service Instructions 867 - 04.0 - 10/2019...
  • Page 25 3. Insert the locking peg (1) with the appropriate end into the slot. Removing the lock To remove the lock: 1. Pull the locking peg (1) out of the slot. 2. Insert the plug into the locking opening (5). Service Instructions 867 - 04.0 - 10/2019...

  • Page 26: Adjusting The Handwheel Into Position

    For some adjustments, the graduated scale (1) on the handwheel has to be moved to a certain position. To adjust the handwheel into position: 1. Turn the handwheel until the specified number on the graduated scale (1) is next to the marking (2). Service Instructions 867 - 04.0 - 10/2019...

  • Page 27: Adjusting The Handwheel Scale

    7. Tighten the threaded pin through the opening (1). 8. Remove the lock ( p. 23). 9. Move the handwheel into the 50° position. 10. Tighten the threaded pin through the opening (1). Service Instructions 867 - 04.0 - 10/2019...

  • Page 28: Positioning The Arm Shaft

    4. 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. 5. Tighten the threaded pins (3). Service Instructions 867 - 04.0 - 10/2019...

  • Page 29: Toothed Belt Wheels

    The 2 threaded pins for the upper toothed belt wheel are seated flush on the flat. Information Additional checks for machines with normal lengths: The distance between the winder wheel and the upper toothed belt wheel is 0.8 mm. Service Instructions 867 - 04.0 - 10/2019...
  • Page 30 Move the upper toothed belt wheel (1) to the side so that the distance to the winder wheel (3) is 0.8 mm. 5. Tighten the threaded pins (2). 6. Use the screwdriver to push the toothed belt (4) back again. Service Instructions 867 - 04.0 - 10/2019...

  • Page 31: Positioning The Lower Toothed Belt Wheel

    4. Move the lower toothed belt wheel (3) sufficiently far to the side so that the toothed belt (1) makes contact with the snap ring (2) without being pushed away. 5. Tighten the threaded pins (4). Service Instructions 867 - 04.0 - 10/2019...

  • Page 32: Adjusting The Stitch Length Adjusting Wheels

    It is not possible to set a larger stitch length on the lower adjusting wheel than on the upper adjusting wheel. It is not possible to set a larger stitch length on the upper adjusting wheel than on the lower adjusting wheel. Service Instructions 867 - 04.0 - 10/2019...

  • Page 33: Adjusting The Upper Stitch Length Adjusting Wheel

    4. Hold the upper stitch length adjusting wheel (1) in place using a wrench (6). 5. Loosen the screw (2). 6. Remove the upper stitch length adjusting wheel (1) from the shaft (4). Service Instructions 867 - 04.0 - 10/2019...

  • Page 34: Adjusting The Lower Stitch Length Adjusting Wheel

     The button turns off. The machine switches over to the lower stitch length adjusting wheel. 4. Hold the lower stitch length adjusting wheel (2) in place using the wrench (6). 5. Loosen the screw (1). Service Instructions 867 - 04.0 - 10/2019...

  • Page 35: Adjusting The Stitch Length Limit

    To adjust the stitch length limit: 1. Position the upper stitch length adjusting wheel (1) to 0. 2. Hold the upper stitch length adjusting wheel (1) in place using the wrench (3). 3. Loosen the screw (2). Service Instructions 867 - 04.0 - 10/2019...

  • Page 36: Adjusting The Eccentric For The Forward And Backward Stitches

    If the forward and backward stitches are not the same length: • Turn clockwise: the forward stitch becomes larger, the backward stitch smaller. • Turn counterclockwise: the forward stitch becomes smaller, the backward stitch larger. 4. Tighten the threaded pin (3). Service Instructions 867 - 04.0 - 10/2019...

  • Page 37: Feed Dog

    • For minimal deviations, it suffices to move the feed dog on the carrier ( p. 36) • If this is not sufficient, move the entire feed dog carrier on the pusher shaft ( p. 37) Service Instructions 867 - 04.0 - 10/2019...

  • Page 38: Moving The Feed Dog

    3. Move the feed dog (1) on the feed dog carrier (2). Place the removed throat plate next to it as an aid for orientation, so that the feed dog can be screwed on straight. 4. Tighten the screws (3). Service Instructions 867 - 04.0 - 10/2019...

  • Page 39: Moving The Feed Dog Carrier

    10. Tighten the rear screw (6). 11. Tighten the connection to the pull rod using the screws (1). Important In the process, make sure that the feed dog height has the correct setting ( p. 39). Service Instructions 867 - 04.0 - 10/2019...

  • Page 40: Adjusting The Feed Dog Movement

    1. Tilt the machine head ( p. 14). 2. Set the upper stitch length adjusting wheel to the maximum stitch length. 3. Loosen the threaded pins (1). 4. Move the handwheel into the 190° position. Service Instructions 867 - 04.0 - 10/2019...

  • Page 41: Adjusting The Feed Dog Height At Top Dead Center

    3. Loosen the threaded pins (2) on the lever (1) at the left, above the hook. 4. Turn the lever (1) such that the upper edge of the feed dog protrudes 0.5 mm (KFA = 0.8 mm) above the throat plate. 5. Tighten the threaded pins (2). Service Instructions 867 - 04.0 - 10/2019...

  • Page 42: Feed Dog Lift (Default)

    (1) - Threaded pins (2) - Stroke eccentric To adjust the stroke movement: 1. Tilt the machine head ( p. 14). 2. Loosen the threaded pins (1). 3. Move the handwheel into the 90° position. Service Instructions 867 - 04.0 - 10/2019...

  • Page 43: Adjusting The Compensating Weight

    4. Turn the compensating weight (2) such that the threaded pin (1) is parallel to the base plate (3). Use the allen key inserted in the threaded pin as a means of orientation. 5. Tighten the threaded pin (1). Service Instructions 867 - 04.0 - 10/2019...

  • Page 44: Feed Dog Lift (Adjustable Stroke Eccentric)

    4. Turn the stroke eccentric (2) such that the upper edge of the feed dog is in the upward movement and at the same height as the upper edge of the throat plate. 5. Tighten the threaded pins (1). Service Instructions 867 - 04.0 - 10/2019...

  • Page 45: Adjusting The Stroke Eccentric

    • Grain (2) in the - range: Reduce the feed dog lift • Grain (2) on the center line: Default feed dog lift 4. Tighten the screws (1). 5. Erect the machine head. 6. Check the feed dog lift and readjust it if necessary. Service Instructions 867 - 04.0 - 10/2019...
  • Page 46 If the sheet of paper cannot be slid or is crushed between feed dog and thread-pulling knife, the feed dog lift must be reduced. Service Instructions 867 - 04.0 - 10/2019...

  • Page 47: Aligning The Needle Bar Linkage

    3. Set the upper and lower stitch length adjusting wheel to 0. 4. Loosen the threaded pins (1) on the two set collars (2) at the right-hand end of the shaft for the needle bar linkage. Service Instructions 867 - 04.0 - 10/2019...
  • Page 48 9. Align the thread lever (7) exactly in the middle of the slot. 10. Tighten the threaded pins (6). Order Then check the following settings: • Looping stroke position ( p. 50) • Distance between hook and needle ( p. 49) Service Instructions 867 - 04.0 - 10/2019...

  • Page 49: Aligning The Needle Bar Linkage In The Sewing Direction

    4. Set the upper stitch length adjusting wheel to 0. 5. Loosen the threaded pins (4). 6. Loosen the screw (5). 7. Position the lever (2). 8. Tighten the threaded pins (4). 9. Tighten the screw (5). Service Instructions 867 - 04.0 - 10/2019...
  • Page 50 Aligning the needle bar linkage Order Then check the following setting: • Looping stroke position ( p. 50) Service Instructions 867 - 04.0 - 10/2019...

  • Page 51: Position Of The Hook And Needle

    Fig. 32: Adjusting the hook side clearance ① ⑥ ⑤ ② ③ ④ (1) - Set collar (4) - Screws (2) - Threaded pins (5) - Needle groove (3) - Hook support (6) - Hook tip Service Instructions 867 - 04.0 - 10/2019...

  • Page 52: Adjusting The Looping Stroke Position

    The looping stroke is precisely 2 mm. Order First, check the following settings: • Needle bar linkage is aligned correctly ( p. 45) Service Instructions 867 - 04.0 - 10/2019...
  • Page 53 8. Remove the lock. Order Then, check the following settings: • Position of the needle guard ( p. 52) • Timing of cutting by the thread trimmer ( p. 73), ( p. 81) Service Instructions 867 - 04.0 - 10/2019...

  • Page 54: Adjusting The Needle Guard

    4. Turn the screw (2) such that the needle guard (3) just pushes the needle (1) far away enough so that it cannot be touched by the hook tip: • Pushing away more strongly: turn counterclockwise • Pushing away less strongly: turn clockwise Service Instructions 867 - 04.0 - 10/2019...

  • Page 55: Adjusting The Needle Bar Height

    The groove (3) must face toward the hook. 4. Tighten the screw (2) for the needle bar (1). Order Then, check the following settings: • Position of the needle guard ( p. 52) Service Instructions 867 - 04.0 - 10/2019...

  • Page 56: Adjusting The Bobbin Case Lifter

    Disturbance Disturbances caused by an incorrect setting of the bobbin case lifter: • Thread breaking • Formation of loops on the bottom side of the seam • Loud machine noise Service Instructions 867 - 04.0 - 10/2019...

  • Page 57: Adjusting The Lifting Gap

    Important Ensure that the gap is not too big. The middle part of the hook must not swing back and forth, hitting the slot in the throat plate (2). Service Instructions 867 - 04.0 - 10/2019...

  • Page 58: 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 867 - 04.0 - 10/2019...

  • Page 59: Sewing Feet

    The left adjusting wheel determines the normal sewing foot stroke. The right adjusting wheel determines the increased sewing foot stroke. The increased sewing foot stroke must NOT be lower than the normal sewing foot stroke. Service Instructions 867 - 04.0 - 10/2019...

  • Page 60: Adjusting An Even Sewing Foot Stroke

    While doing so, make sure that the walking foot is only lowered down to the throat plate. Do not inadvertently lower the walking foot through the throat plate cutout down to the feed dog. 5. Tighten the screw (3). Service Instructions 867 - 04.0 - 10/2019...

  • Page 61: Adjusting The Stroke Movement For The Walking Foot

    To adjust the stroke movement for the walking foot: 1. Disassemble the arm cover ( p. 15). 2. Screw in the threaded pin (6) so that there is a stroke. 3. Set the upper stitch length adjusting wheel to 0. Service Instructions 867 - 04.0 - 10/2019...

  • Page 62: Adjusting The Sewing Foot Pressure

    (1) - Adjusting wheel for the sewing foot pressure To adjust the sewing foot pressure: 1. Turn the adjusting wheel for the sewing foot pressure (1): • greater pressure: turn clockwise • lower pressure: turn counterclockwise Service Instructions 867 - 04.0 - 10/2019...

  • Page 63: Adjusting The Sewing Foot Lifting Height

    2. Turn the screw (1) to adjust the distance between the raised sewing feet and the throat plate: • Raise the sewing feet to a lesser height: turn clockwise • Raise the sewing feet higher: turn counterclockwise 3. Tighten the counternut (2). Service Instructions 867 - 04.0 - 10/2019...

  • Page 64: Adjusting The Needle Thread Tension

    (2) - Needle thread regulator 1. Open the throat plate slides ( p. 18). 2. Turn the handwheel and observe the cycle of the needle thread around the hook. 3. Loosen the screw (1). Service Instructions 867 - 04.0 - 10/2019...

  • Page 65: Adjusting The Thread Tensioning Spring

    3. Turn the tension disk (3) to set the spring tension. • Greater spring tension: turn counterclockwise • Lower spring tension: turn clockwise Important Do not twist the stop collar in doing so. 4. Tighten the screw (4). Service Instructions 867 - 04.0 - 10/2019...

  • Page 66: Winder

    1. Loosen the threaded pins (1). 2. Move the driver wheel (2) to the right or left so that the distance to the winder wheel (3) is exactly 0.8 mm. 3. Tighten the threaded pins (1). Service Instructions 867 - 04.0 - 10/2019...

  • Page 67: Adjusting The Winder

    • Arms (4) further apart from each other: turn clockwise 5. Put the completely filled bobbin onto the winder. 6. Fold the winder lever (3) upwards as far as it will go to the thread. Service Instructions 867 - 04.0 - 10/2019...
  • Page 68 10. Adjust the block (8) such that it is resting against the locking disk (9). 11. Adjust the block (8) such that its distance to the winder wheel (10) is 0.5 mm. 12. Tighten the threaded pin in the block (8). Service Instructions 867 - 04.0 - 10/2019...
  • Page 69 16. Tighten the threaded pin (13). Assembling the winder Fig. 54: Adjusting the winder (5) ① (1) - Screws To assemble the winder: 17. Place the winder on the machine arm. 18. Tighten the screws (1). Service Instructions 867 - 04.0 - 10/2019...

  • Page 70: Adjusting The Hook Thread Guide

    2. Turn the hook thread guide (2): • To the front: The hook thread will be wound on further to the front • To the rear: The hook thread will be wound on further to the rear Service Instructions 867 - 04.0 - 10/2019...

  • Page 71: Thread Trimmer

    When changing the knives, make sure that you do not lose the washers. Proper setting The thread-pulling knife (2) pivots as closely as possible above the hook and is at the same height as the counter blade (1). Service Instructions 867 - 04.0 - 10/2019...

  • Page 72: Adjusting The Cutoff Curve

    3. Loosen the threaded pins (3) on the set collar (2). 4. Push the set collar (2) as far as it will go to the left. 5. Tighten the threaded pins (3) on the set collar (2). Service Instructions 867 - 04.0 - 10/2019...
  • Page 73 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. 50). 17. Tighten the threaded pins (3) on the set collar (2). Service Instructions 867 - 04.0 - 10/2019...

  • Page 74: Adjusting The Cutting Pressure

    6. Turn the counter blade (2) so that it rests against the thread-pulling knife (3). 7. Tighten the screw (1). 8. Check the position of the knife, as the counter blade can easily become warped when the screw is being tightened. Service Instructions 867 - 04.0 - 10/2019...

  • Page 75: Adjusting Point In Time For Cutting

    • Insert the thread into thread-pulling knife (4) and slowly turn the handwheel. • Check the handwheel position at which the thread is cut. 11. If necessary, repeat adjustment steps 1 – 7 until the cut takes place at 60°. Service Instructions 867 - 04.0 - 10/2019...

  • Page 76: Short Thread Cutter (Kfa)

    Cover • Open the throat plate slides ( p. 18) • Disassemble the throat plate ( p. 19) • Disassemble the feed dog ( p. 20) Service Instructions 867 - 04.0 - 10/2019...

  • Page 77: General Information

    The height of the thread-pulling knife has been set at the factory using adjusting washers between thread-pulling knife (1) and knife carrier (3). When changing the knives make sure that you do not lose the adjusting washers. Service Instructions 867 - 04.0 - 10/2019...
  • Page 78 (label is upside down) of the set collar (4). Proper setting The control cam (5) makes contact with the set collar (4). The label of the control cam (5) is correct in accordance with the installa- tion situation. Service Instructions 867 - 04.0 - 10/2019...

  • Page 79: Adjusting The Locking Latch

    2. Press the roller (2) against the control cam (3).  The locking latch (1) can be swung out without clamping. The distance between the locking latch (1) and locking pin (6) is not greater than 0.1 mm. Service Instructions 867 - 04.0 - 10/2019...

  • Page 80: Adjusting The Thread-Pulling Knife

    8. Turn the thread-pulling knife (1) until the marking (3) on the cutting edge of the counter blade (2) is adjacent to it. 9. Tighten the clamping screw (9). Take care to ensure that there is no axial play. Service Instructions 867 - 04.0 - 10/2019...

  • Page 81: Adjusting The Counter Blade

    5. Check whether the sewing threads have been cleanly cut and pressure is built up starting at the marking (2). Disturbance Disturbances caused by an incorrect setting: • Increased knife wear when the pressure is too great • Problems in cutting the thread Service Instructions 867 - 04.0 - 10/2019...
  • Page 82 4. Swing out the thread-pulling knife (3) until the marking (2) is next to the cutting edge of the counter blade (1). 5. Loosen the screw (4). 6. Place the counter blade (1) in position against the thread-pulling knife (3). 7. Tighten the screw (4). Service Instructions 867 - 04.0 - 10/2019...

  • Page 83: 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 cut was made at the 65° position on the handwheel. Service Instructions 867 - 04.0 - 10/2019...
  • Page 84 2. Move the control cam (5) towards the set collar (4) until it makes contact and correct the position of the control cam (5). 3. Tighten the threaded pins (6) on the control cam (5). 4. Check and, if necessary, correct the cutting position. Service Instructions 867 - 04.0 - 10/2019...

  • Page 85: Adjusting The Potentiometer

    5. Calling the technician level using the Plus/Minus buttons (3): As the case may be, press the Plus or Minus button below the letter or the number until the display indicates t 10 04. 6. Press the OK button. Service Instructions 867 - 04.0 - 10/2019...
  • Page 86 13. Tighten the threaded pin (8) without changing the value shown in the display. 14. Press the ESC button two times. Important 15. Switch off the machine. 16. Switch on the machine.  Switching off and on will save the adjustment. Service Instructions 867 - 04.0 - 10/2019...

  • Page 87: Adjusting The Safety Snap-On Coupling

    1. Tilt the machine head ( p. 14). 2. Turn the left set collar (2) such that the threaded pins (1) are parallel to one another.  The safety release clutch latches into place. Service Instructions 867 - 04.0 - 10/2019...

  • Page 88: Adjusting The Torque

    3. Using the screw driver, turn the disk on the adjustment slot (5) 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 (7). Service Instructions 867 - 04.0 - 10/2019...

  • Page 89: Machines With Integrated Motor

    ② ① ⑤ ⑥ ⑦ ⑧ (1) - Handwheel (5) - Cover plate (2) - Handwheel flange (6) - Stator (3) - Encoder (7) - Ring (4) - Encoder disk (8) - Rotor Service Instructions 867 - 04.0 - 10/2019...

  • Page 90: Disassembling The Drive

    (4) - Threaded pins To disassemble the handwheel and handwheel flange: 1. Loosen the screws (2). 2. Disassemble the handwheel (1). 3. Loosen the threaded pins (3). 4. Disassemble the handwheel flange (4). Service Instructions 867 - 04.0 - 10/2019...

  • Page 91: Disassembling The Cover

    2. Carefully remove the upper cover (2) from the side, paying attention to the adjusting wheel (3) in doing so. If there is a lower cover mounted: 3. Loosen the screws (5). 4. Remove the lower cover (4). Service Instructions 867 - 04.0 - 10/2019...

  • Page 92: Disassembling The Encoder

    4. Loosen the screws on the encoder (2). 5. Loosen the screw on the encoder disk (1). 6. Carefully and uniformly pull the encoder (2) and encoder disk (1) away from the shaft. Service Instructions 867 - 04.0 - 10/2019...

  • Page 93: Disassembling The Stator

    (1) - Screws (3) - Stator with ring (2) - Plate To disassemble the stator: 1. Loosen the screws (1). 2. Pull off the plate (2). 3. Remove the stator with ring (3). Service Instructions 867 - 04.0 - 10/2019...

  • Page 94: Disassembling The Rotor

    (2) - Threaded pins To disassemble the rotor: 1. Disassemble the arm cover ( p. 15). 2. Loosen threaded pins (1) and (2). 3. Remove the rotor with deep groove ball bearing (3). Service Instructions 867 - 04.0 - 10/2019...

  • Page 95: Assembling The Drive

    2. Tighten threaded pins (1) and (2). Observe the surface of the shaft in doing so: Tighten the 1 screw in the direction of rotation firmly in place on the surface. Service Instructions 867 - 04.0 - 10/2019...

  • Page 96: Assembling The Stator

    In doing so, pay attention to the ring gap for the cable. Place the plate (2). 2. Evenly tighten the screws (1) firmly in place so that a uniform gap exists between the plate (2) and shaft. Service Instructions 867 - 04.0 - 10/2019...

  • Page 97: Assembling The Encoder

    (2). 3. Screw the encoder disk (1) and encoder (2) firmly in place. 4. Tighten the plate (3). 5. Insert plugs L1, L2, and L3 (5). 6. Insert the encoder plug (4). Service Instructions 867 - 04.0 - 10/2019...

  • Page 98: Assembling The Cover

    1. Carefully attach the upper cover (2) from the side. Pay attention to the adjusting wheel (3) in doing so. 2. Tighten the screws (1). 3. Attach the lower cover (5). 4. Tighten the screws (4). Service Instructions 867 - 04.0 - 10/2019...

  • Page 99: Locking The Machine In Place

     The needle is in the top dead center position. 19.3.6 Assembling the handwheel flange Fig. 83: Assembling the handwheel flange ④ ① ② ③ (1) - Handwheel flange (3) - Marking (2) - Marking (4) - Threaded pins Service Instructions 867 - 04.0 - 10/2019...

  • Page 100: Assembling The Handwheel

    (1) - Handwheel (2) - Screws To assemble the handwheel: 1. Attach the handwheel (1). 2. Tighten the screws (2). 3. Adjust the reference position via the control; see  Instructions for use DAC basic/classic. Service Instructions 867 - 04.0 - 10/2019...

  • Page 101: Replacing The Fuse Of The Sewing Light Transformer

    2. Loosen the screws (1) for the carrier plate of the PCB. 3. Replace the PCB (2). 4. Tighten the screws (1). 5. Insert plugs. Important Ensure that the motor is correctly connected! Service Instructions 867 - 04.0 - 10/2019...

  • Page 102: Special Machines

    ① ① (1) - Needle holder To adjust the needle bar height: 1. Set the stitch length adjusting wheel to 0. 2. Lock the machine in place at position 1 ( p. 22). Service Instructions 867 - 04.0 - 10/2019...
  • Page 103 (1) rests in the hexagon socket of the threaded pin (4). 9. Tighten the threaded pins (3). Order After correcting the needle bar height, check the position of the needle guard ( p. 52). Service Instructions 867 - 04.0 - 10/2019...

  • Page 104: Adjusting The Slide

    (2) - Slide (4) - Center of pin To adjust the slide: 1. Loosen the screws (1). 2. Adjust slide (2). 3. Tighten the screws (1). 4. Check whether the needle bars switch cleanly. Service Instructions 867 - 04.0 - 10/2019...

  • Page 105: Machines With Moving Binder

    To adjust the basic setting for synchronous operation: 1. Set the handwheel to 100°.  The shaft (5) must be parallel to the hook shaft (6). 2. Remove the shaft (5). 3. Check for synchronous operation. Service Instructions 867 - 04.0 - 10/2019...

  • Page 106: Machines With Edge Trimmer

    The knife cuts the sewing material when material is not being fed. Fig. 91: Adjusting the time for knife movement ① ② ③ (1) - Threaded pins (3) - Toothed belt wheel (2) - Edge trimmer Service Instructions 867 - 04.0 - 10/2019...

  • Page 107: Adjusting The Knife Stroke

    1. Disassemble the cover (1). 2. Loosen the nut (3). 3. Turn the screw (4): • Increase the knife stroke: Turn screw upwards • Reduce the knife stroke: Turn screw downwards 4. Tighten the nut (3). Service Instructions 867 - 04.0 - 10/2019...

  • Page 108: Adjusting The Blade Overlap

    (3) - Screws (2) - Knife holder (4) - Counter blade The knife (2) should be somewhat diagonal to the counter blade (3). The knife (2) should cut reliably with the least possible pressure. Service Instructions 867 - 04.0 - 10/2019...

  • Page 109: Programming

    (1) - Power LED (5) - Seam program button group (2) - Thread button group (6) - LED for 2 stitch length (3) - Function button (7) - Display (4) - Programming button group Service Instructions 867 - 04.0 - 10/2019...
  • Page 110 Soft start • Activates or deactivates the soft start Speed • Reduces the motor speed Function button • Activates or deactivates any stored function Programming button group • Ends parameter mode Service Instructions 867 - 04.0 - 10/2019...
  • Page 111 • Starts or ends the parameter mode • Decreases parameter • Changes user level • Selects subprogram • Decreases parameter • Changes to next lower category • Selects subprogram • Decreases parameter • Selects subprogram Service Instructions 867 - 04.0 - 10/2019...
  • Page 112 • Resets the (piece) counter Seam program button group Seam program I • Activates seam program I Seam program II • Activates seam program II Seam program III • Sets seam program III Service Instructions 867 - 04.0 - 10/2019...

  • Page 113: Activating The Tensioner Lift

     You are on the technician level. 2. Use the buttons under the display to select the parameter t 09 00. 3. Use +/- to enter the desired value ( Parameter list 867). 4. Confirm with Service Instructions 867 - 04.0 - 10/2019...

  • Page 114: Activating The Nsb

     The NSB has been activated in the software. 6. Check all NSB parameters and adjust them if necessary (See  Parameter list 867). 7. To activate the NSB during sewing, press the button. Service Instructions 867 - 04.0 - 10/2019...

  • Page 115: Maintenance

    Check the hook lubrication Pneumatic system  Adjusting the operating pressure  Draining the water-oil mixture  Cleaning the filter element Specific components  Cleaning the motor fan mesh  Checking the toothed belt Service Instructions 867 - 04.0 - 10/2019...

  • Page 116: Cleaning

    Lint and thread remnants should be removed after every 8 operating hours using a compressed air gun or a brush. If very fluffy sewing material is being sewn the machine must be cleaned more frequently. Service Instructions 867 - 04.0 - 10/2019...
  • Page 117 • Area under the throat plate (3) • Hook (2) • Area around the needle (1) To clean the machine: 1. Remove any lint and thread remnants using a compressed air gun or a brush. Service Instructions 867 - 04.0 - 10/2019...

  • Page 118: Lubricating

    • Flash point: 150 °C You can order the lubricating oil from our sales offices using the following part numbers: Container Part no. 250 ml 9047 000011 9047 000012 9047 000013 9047 000014 Service Instructions 867 - 04.0 - 10/2019...

  • Page 119: Lubricating The Machine Head

    1. Fill oil through the oil filler opening (1) up to the MAX marking (2). 2. Turn the machine off, then on again after refilling oil.  The red light will turn off. Service Instructions 867 - 04.0 - 10/2019...

  • Page 120: Adjusting The Hook Lubrication

    • Release less oil: turn 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 867 - 04.0 - 10/2019...

  • Page 121: Servicing The Pneumatic System

    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 867 - 04.0 - 10/2019...

  • Page 122: Draining The Water-Oil Mixture

    2. Place the vessel under the drain screw (3). 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 867 - 04.0 - 10/2019...

  • Page 123: 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 867 - 04.0 - 10/2019...

  • Page 124: Servicing Specific Components

    Fig. 103: Cleaning the motor fan mesh ① ② (1) - Tabletop (2) - Motor fan mesh To clean the motor fan mesh: 1. Remove any lint and thread remnants using a compressed air gun. Service Instructions 867 - 04.0 - 10/2019...

  • Page 125: Checking The Toothed Belt

    When pressed with a finger, the toothed belt must yield no more than 10 mm. 22.5 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 867 - 04.0 - 10/2019...
  • Page 126 Maintenance Service Instructions 867 - 04.0 - 10/2019...

  • Page 127: 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 867 - 04.0 - 10/2019...
  • Page 128 Decommissioning Service Instructions 867 - 04.0 - 10/2019...

  • Page 129: 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 867 - 04.0 - 10/2019...
  • Page 130 Disposal Service Instructions 867 - 04.0 - 10/2019...

  • Page 131: Troubleshooting

    (Sub-D, 9-pin) not DACextension box using the correct connected to connection DACextension box 2120 DA stepper card 1 not • Check connection cables responding • Check LEDs of DACextension box • Software update Service Instructions 867 - 04.0 - 10/2019...
  • Page 132 Bobbin failed to rotate 6360 No valid data on external • Software update EEprom (internal data structures are not compatible with the external data storage device) 6361 No external EEprom • Connect machine ID connected Service Instructions 867 - 04.0 - 10/2019...
  • Page 133 • Check connection cables error • Software update • Replace DACextension box 7223 Checksum error occurred • Check connection cables while updating DA stepper • Software update card 2 • Replace DACextension box Service Instructions 867 - 04.0 - 10/2019...

  • Page 134: Error Messages

    • Test sewing motor phases and check for correct value 1005 Error Sewing motor blocked • Eliminate stiff movement in the machine • Replace encoder • Replace sewing motor Service Instructions 867 - 04.0 - 10/2019...
  • Page 135 DA stepper card 2 reference • Check reference sensor run timeout 2203 Error DA stepper card 2 step • Check for stiff movement losses 2255 Error DA stepper card 2 overload • Check for stiff movement Service Instructions 867 - 04.0 - 10/2019...
  • Page 136 • Wait until the LEDs are off • Check machine ID connection • Switch the control back on 8401 Error Watchdog • Software update • Machine ID reset • Replace control Service Instructions 867 - 04.0 - 10/2019...

  • Page 137: Errors In Sewing Process

    Thread-guiding parts, such Check threading path as thread tube, thread guide or thread take-up disk, are sharp-edged Throat plate, hook or Have parts reworked by qualified spread have been specialists damaged by the needle Service Instructions 867 - 04.0 - 10/2019...
  • Page 138 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 867 - 04.0 - 10/2019...

  • Page 139: Technical Data

    = 79 dB (A); K = ± 0.64 dB (A) at • Stitch length: 6.0 mm • Alternating sewing foot stroke: 1.5 mm • Speed: 2200 rpm • Sewing material: 4-layer material G1 DIN 23328 Service Instructions 867 - 04.0 - 10/2019...

  • Page 140: Data Overview By Subclasses

    (*only with reversing mechanism) Maximum sewing foot stroke Positive operating pressure [bar] Air consumption [NL] Length/width/height [mm] 690/220/460 Weight/with direct drive [kg] 55/59 Rated voltage [V, Hz] 230, 50/60 Rated power [kVA] 0.75 Service Instructions 867 - 04.0 - 10/2019...
  • Page 141 Maximum sewing foot stroke Positive operating pres- sure [bar] Air consumption [NL] Length/width/height [mm] 690/220/460 690/320/460 Weight/with direct drive 55/59 [kg] Rated voltage [V, Hz] 230, 50/60 Rated power [kVA] 0.75 Service Instructions 867 - 04.0 - 10/2019...
  • Page 142 Rated voltage [V, Hz] 230, 50/60 Rated power [kVA] 0.75 ** For 2-needle machines equipped with the DC1550-DA321G and a motor assembled to the machine head, the maximum possible speed is 3,000 rpm. Service Instructions 867 - 04.0 - 10/2019...
  • Page 143 [bar] Air consumption [NL] Length/width/height 1090/220/460 1390/ [mm] 220/ Weight/with direct drive 85/89 95/99 [kg] Rated voltage [V, Hz] Depends on the drive package Rated power [W] Depends on the drive package Service Instructions 867 - 04.0 - 10/2019...
  • Page 144 Stitch length, 12/12 12/12 forwards/ backwards [mm] Number of adjustable stitch lengths Maximum Number of stitches Number of 3000 3400 stitches on delivery Maximum Stroke height (*only with reversing mechanism) Service Instructions 867 - 04.0 - 10/2019...
  • Page 145 Vertical hook, extra- large (XXL) Number of needles Needle system 134-35 Maximum needle strength [Nm] Maximum 80/3-10/3 Sewing thread (up to 15/3 and 20/3, respectively, with short thread cutter and thickness neat seam beginning) Service Instructions 867 - 04.0 - 10/2019...
  • Page 146 Maximum Stroke height (*only with reversing mechanism) Maximum Sewing foot stroke Positive operating pressure [bar] Air consumption [NL] Length/width/height 740/220/460 [mm] Weight/with direct drive [kg] Rated voltage [V, 230, 50/60 Rated power [W] Service Instructions 867 - 04.0 - 10/2019...
  • Page 147 Maximum stroke height (*only with reversing mechanism) Maximum sewing foot stroke Positive operating pressure [bar] Air consumption [NL] Length/width/height [mm] 1090/220/460 Weight/with direct drive [kg] Rated voltage [V, Hz] 230, 50/60 Rated power [W] Service Instructions 867 - 04.0 - 10/2019...
  • Page 148 (*Only with reversing mechanism) Maximum sewing foot stroke Positive operating pressure [bar] Air consumption [NL] Length/width/height [mm] 1090/220/460 1390/ 220/ Weight/with direct drive [kg] Rated voltage [V, Hz] 230, 50/60 Rated power [W] Service Instructions 867 - 04.0 - 10/2019...

  • Page 149: Permissible Maximum Speeds

    2500 2500 2500 2500 2500 2500 Stroke 6-9 1800 1800 1800 1800 1800 1800 Stitch length 9-12 Stroke 1-5 2000 2000 2000 2000 2000 2000 Stroke 6-9 1800 1800 1800 1800 1800 1800 Service Instructions 867 - 04.0 - 10/2019...
  • Page 150 Stroke 6-9 1800 1800 1800 1800 1800 1800 1800 1800 1800 Stitch length Stroke 1-5 2000 2000 2000 2000 2000 2000 2000 2000 2000 9-12 Stroke 6-9 1800 1800 1800 1800 1800 1800 1800 1800 1800 Service Instructions 867 - 04.0 - 10/2019...
  • Page 151 Stroke 5 2500 2500 2500 2500 2500 3100 2500 Stroke 1800 1800 1800 1800 1800 2500 1800 Stitch length Stroke 2000 2000 2000 2000 2000 2000 9-12 Stroke 1800 1800 1800 1800 1800 1800 Service Instructions 867 - 04.0 - 10/2019...
  • Page 152 2500 2500 2500 2500 2500 2500 2500 2500 2500 2500 2500 Stroke 1800 1800 1800 1800 1800 1800 1800 1800 1800 1800 1800 Stitch length Stroke 2000 2000 2000 2000 2000 2000 2000 9-12 Stroke 1800 1800 1800 1800 1800 1800 1800 Service Instructions 867 - 04.0 - 10/2019...
  • Page 153 2000 2000 2000 2000 2000 2000 Stroke 6-9 1800 1800 1800 1800 1800 1800 Stitch length 9-12 Stroke 1-5 2000 2000 2000 2000 2000 2000 Stroke 6-9 1800 1800 1800 1800 1800 1800 Service Instructions 867 - 04.0 - 10/2019...

  • Page 154: Requirements For Fault-Free Operation

    Stroke 1-5 2000 2000 2000 2000 2000 2000 2000 9-12 Stroke 6-9 1800 1800 1800 1800 1800 1800 1800 26.4 Requirements for fault-free operation Compressed air quality must conform to ISO 8573-1: 2010 [7:4:4]. Service Instructions 867 - 04.0 - 10/2019...

  • Page 155: Appendix

    Appendix 27 Appendix Wiring diagram Fig. 104: Wiring diagram Service Instructions 867 - 04.0 - 10/2019...
  • Page 156 Appendix Fig. 105: Wiring diagram Service Instructions 867 - 04.0 - 10/2019...
  • Page 157 Appendix Fig. 106: Wiring diagram Service Instructions 867 - 04.0 - 10/2019...
  • Page 158 Appendix Fig. 107: Wiring diagram Service Instructions 867 - 04.0 - 10/2019...
  • Page 159 Appendix Fig. 108: Wiring diagram Service Instructions 867 - 04.0 - 10/2019...
  • Page 160 Appendix Fig. 109: Wiring diagram Service Instructions 867 - 04.0 - 10/2019...
  • Page 161 Appendix Fig. 110: Wiring diagram Service Instructions 867 - 04.0 - 10/2019...
  • Page 162 Appendix Fig. 111: Wiring diagram Service Instructions 867 - 04.0 - 10/2019...
  • Page 164 DÜRKOPP ADLER AG Potsdamer Straße 190 33719 Bielefeld GERMANY Phone +49 (0) 521 / 925-00 E-mail service@duerkopp-adler.com www.duerkopp-adler.com...

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