Dürkopp Adler 868-M Operating Instructions Manual
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Dürkopp Adler 868-M Operating Instructions Manual

Dürkopp Adler 868-M Operating Instructions Manual

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868-M
Operating Instructions

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Summary of Contents for Dürkopp Adler 868-M

  • Page 1 868-M Operating 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 2020...

  • Page 3: Table Of Contents

    Limiting of number of stitches with an increased sewing foot stroke... 57 4.11.2 Setting the sewing foot stroke ............. 58 4.11.3 Quick stroke adjustment via knee button ..........60 4.12 Lifting the sewing feet................61 4.12.1 Mechanical lifting with the knee lever ..........61 Operating Instructions 868-M - 01.0 - 12/2020...
  • Page 4 Inserting the machine head ............... 119 Setting the working height ..............122 Setting the pedal ................123 7.10 Assembling the control panel ............124 7.11 Assembling the knee lever / knee button .......... 125 Operating Instructions 868-M - 01.0 - 12/2020...
  • Page 5 Error messages ................. 142 10.3 Errors in sewing process ..............146 Technical data ................. 149 11.1 Data and characteristic values ............149 11.2 Permissible maximum speeds............150 11.3 Characteristics................... 151 Appendix ..................153 Operating Instructions 868-M - 01.0 - 12/2020...
  • Page 6 Table of Contents Operating Instructions 868-M - 01.0 - 12/2020...

  • Page 7: About These Instructions

    Specifically, the chapter Setup ( p. 109) is important for specialists. Service Instructions are supplied separately. With regard to minimum qualification and other requirements to be met by personnel, please also follow the chapter Safety ( p. 9). Operating Instructions 868-M - 01.0 - 12/2020...

  • Page 8: Representation Conventions - Symbols And Characters

    Lists are marked by bullet points.  Result of performing an operation Change to the machine or on the display/control panel. Important Special attention must be paid to this point when performing a step. Operating Instructions 868-M - 01.0 - 12/2020...

  • Page 9: Other Documents

    Each manufacturer has performed a hazard assessment for these purchased parts and confirmed their design compliance with applicable European and national regulations. The proper use of the built-in components is described in the corresponding manu- facturer's instructions. Operating Instructions 868-M - 01.0 - 12/2020...

  • Page 10: Liability

    Leave machines, equipment and packaging material in the con- dition 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. Operating Instructions 868-M - 01.0 - 12/2020...

  • Page 11: Safety

    The power plug may only be assembled to the power cable by qualified specialists. Obligations Follow the country-specific safety and accident prevention regu- of the operator lations and the legal regulations concerning industrial safety and the protection of the environment. Operating Instructions 868-M - 01.0 - 12/2020...

  • Page 12: Signal Words And Symbols Used In Warnings

    Signal words Signal words and the hazard they describe: Signal word Meaning DANGER (with hazard symbol) If ignored, fatal or serious injury will result WARNING (with hazard symbol) If ignored, fatal or serious injury can result Operating Instructions 868-M - 01.0 - 12/2020...
  • Page 13 If ignored, environmental damage can result NOTICE (without hazard symbol) If ignored, property damage can result Symbols The following symbols indicate the type of danger to personnel: Symbol Type of danger General Electric shock Puncture Crushing Environmental damage Operating Instructions 868-M - 01.0 - 12/2020...
  • 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 moderate or minor injury if the warning is ignored. Operating Instructions 868-M - 01.0 - 12/2020...
  • Page 15 CAUTION 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 environmental damage if ignored. Operating Instructions 868-M - 01.0 - 12/2020...
  • Page 16 Safety Operating Instructions 868-M - 01.0 - 12/2020...

  • Page 17: Machine Description

    (8) - Knee button (3) - Needle bar (9) - Control (DAC classic) (4) - Hook (10) - Stitch adjustment lever (5) - Tabletop (11) - Winder (6) - Stand (12) - Reel stand Operating Instructions 868-M - 01.0 - 12/2020...

  • Page 18: Proper Use

    DIN EN 60204-31. Only authorized persons may work on the machine. Dürkopp Adler cannot be held liable for damages resulting from improper use. Operating Instructions 868-M - 01.0 - 12/2020...

  • Page 19: Declaration Of Conformity

    Machine description Declaration of Conformity The machine complies with European regulations ensuring health, safety, and environmental protection as specified in the declara- tion of conformity or in the declaration of incorporation. Operating Instructions 868-M - 01.0 - 12/2020...
  • Page 20 Machine description Operating Instructions 868-M - 01.0 - 12/2020...

  • Page 21: Operation

    • Inserting/changing the needle ( p. 24) • Threading the needle thread ( p. 28) • Inserting and winding on the hook thread ( p. 41) • Setting the thread tension ( p. 47) Operating Instructions 868-M - 01.0 - 12/2020...

  • Page 22: Switching On And Off The Machine

    Fig. 3: Switching on and off the machine (2) ③ ② (2) - LED light (3) - LED light  LED lights (2) and (3) are lit, indicating that the machine is ready for use. Operating Instructions 868-M - 01.0 - 12/2020...

  • Page 23: Switching On And Off The Sewing Lamp

    / the machine itself. Fig. 4: Switching on and off the sewing lamp (1) ① (1) - Switch Switching on the sewing lamp To switch on the sewing lamp: Set the switch (1) to position I. Operating Instructions 868-M - 01.0 - 12/2020...
  • Page 24 Setting the brightness To set the brightness of the external/integrated sewing lamp: Press and hold button (2)/(3) until the sewing lamp flashes briefly.  You can now set the brightness. Operating Instructions 868-M - 01.0 - 12/2020...
  • Page 25 To switch off the external sewing lamp, press button (3).  The sewing lamp is no longer lit. Set the switch (1) to position 0.  The sewing lamps are now powered off. Operating Instructions 868-M - 01.0 - 12/2020...

  • Page 26: Inserting/Changing The Needle

    There is a risk of machine damage, needle breakage or thread breakage if the distance between needle and hook tip is incorrect. Check the distance to the hook tip after inserting a needle with a different thickness. Operating Instructions 868-M - 01.0 - 12/2020...

  • Page 27: In 1-Needle Machines

    Align the new needle in such a way that the groove (3) faces the hook. Tighten the screw (2). Order Always adjust the clearance between the hook and the needle after changing to a different needle thickness ( Service Instructions). Operating Instructions 868-M - 01.0 - 12/2020...

  • Page 28: In 2-Needle Machines

    To change the left needle, loosen the left screw (2). Pull the needle(s) downwards out of the needle holder (4). Insert new needle(s) into the corresponding hole of the needle holder (4) until you reach the stop. Operating Instructions 868-M - 01.0 - 12/2020...
  • Page 29 An incorrect hook distance can cause the following disturbances: • Changing to a thinner needle: • Missing stitches • Thread damage • Changing to a thicker needle: • Damage to the hook tip • Damage to the needle Operating Instructions 868-M - 01.0 - 12/2020...

  • Page 30: Threading The Needle Thread

    To thread the needle thread: Fit the thread reel on the reel stand. The unwinding bracket (1) must stand directly above the thread reel. Fig. 8: In 1-needle machines (1) ① (1) - Unwinding bracket Operating Instructions 868-M - 01.0 - 12/2020...
  • Page 31 (7) - Thread tension spring (3) - Thread guide (8) - Tightening lever (4) - Needle thread regulator (9) - Additional tensioner (5) - Hook (10) - Main tensioner (6) - Spring tip (11) - Pre-tensioner Operating Instructions 868-M - 01.0 - 12/2020...
  • Page 32 10. Pull the needle thread under the spring tip (6). 11. Guide the needle thread under the hook (5). 12. Insert the needle thread from the bottom through the hole on the needle thread regulator (4). Operating Instructions 868-M - 01.0 - 12/2020...
  • Page 33 For machines with thread clamp (optional) 15. Insert the needle thread through the right hole of the thread guide above the thread clamp (14). 16. Insert the needle thread through the right hole of the thread clamp (15). Operating Instructions 868-M - 01.0 - 12/2020...
  • Page 34 Fig. 13: In 1-needle machines (6) ⑯ ⑰ (16) - Thread guide (17) - Thread guide of the needle bar Operating Instructions 868-M - 01.0 - 12/2020...
  • Page 35 If the loose thread end is too long, the needle thread may be caught by the hook and cause a disturbance. If the loose thread end is too short, the machine cannot start sewing. Operating Instructions 868-M - 01.0 - 12/2020...

  • Page 36: In 2-Needle Machines

    To thread the right and the left needle thread: Fit the thread reels on the reel stands. The unwinding bracket (1) must stand directly above the thread reels. Fig. 15: In 2-needle machines (1) ① (1) - Unwinding bracket Operating Instructions 868-M - 01.0 - 12/2020...
  • Page 37 Insert the right needle thread from the rear to the front through the right thread guide on the unwinding bracket (1). Insert the left needle thread from the rear to the front through the left thread guide on the unwinding bracket (1). Operating Instructions 868-M - 01.0 - 12/2020...
  • Page 38 Guide the needle thread clockwise around the pre-tensioner (9). Guide the needle thread counterclockwise around the addi- tional tensioner (7). Operating Instructions 868-M - 01.0 - 12/2020...
  • Page 39 3 left holes of the thread guide (3): From the center at the top right to the bottom, from the bottom to the top and from the top to the bottom. 14. Guide the needle thread clockwise around the pre-tensioner (10). Operating Instructions 868-M - 01.0 - 12/2020...
  • Page 40 23. Thread the left needle thread from the bottom through the rear hole on the needle thread regulator (14). 24. Thread the right needle thread from the right through the lower hole on the thread lever (13). Operating Instructions 868-M - 01.0 - 12/2020...
  • Page 41 (17) and (19). 30. Insert the left needle thread through the left hole of the thread clamp (18). 31. Insert the right needle thread through the right hole of the thread guide (19). Operating Instructions 868-M - 01.0 - 12/2020...
  • Page 42 If the loose thread end is too long, the needle thread may be caught by the hook and cause a disturbance. If the loose thread end is too short, the machine cannot start sewing. Operating Instructions 868-M - 01.0 - 12/2020...

  • Page 43: Winding The Hook Thread

    To thread the hook thread: Fit the thread reel on the reel stand. The unwinding bracket (1) must stand directly above the thread reel. Fig. 22: Winding the hook thread (1) ① (1) - Unwinding bracket Operating Instructions 868-M - 01.0 - 12/2020...
  • Page 44 (4): From the top into the left hole, from the bottom into the center hole, and from the top into the right hole.  The last hole is the hole on the far right in the thread guide (4). Operating Instructions 868-M - 01.0 - 12/2020...
  • Page 45 14. Remove the full bobbin from the bobbin shaft (8). 15. Tear off the hook thread behind the cutter (9). You can now fill the next bobbin. You can insert the full bobbin into the hook. Operating Instructions 868-M - 01.0 - 12/2020...

  • Page 46: Changing The Bobbin

    (1) light up on the machine arm. The left light is for the left-hand hook, and the right light is for the right-hand hook. Fig. 26: Changing the bobbin ① (1) - LED indicator lamp Operating Instructions 868-M - 01.0 - 12/2020...

  • Page 47: Changing The Right Bobbin

    Swivel up the bobbin case retainer (6). Remove the empty bobbin. Insert a full bobbin: Important Insert the bobbin so that it moves in the opposite direction of the hook when the thread is pulled out. Operating Instructions 868-M - 01.0 - 12/2020...

  • Page 48: Changing The Left Bobbin

    The left hook has the same design as the right hook, but is rotated by 180°. To change the left bobbin: Change the left bobbin following the same order as for the right bobbin ( p. 45). Operating Instructions 868-M - 01.0 - 12/2020...

  • Page 49: Thread Tension

    Fig. 29: Thread tension ① ② ③ (1) - Identical needle thread and hook thread tension (2) - Hook thread tension higher than needle thread tension (3) - Needle thread tension higher than hook thread tension Operating Instructions 868-M - 01.0 - 12/2020...

  • Page 50: Setting The Needle Thread Tension

    Puncture, cutting and crushing possible. Switch off the machine before setting the needle thread tension. Fig. 30: Setting the needle thread tension (1) ① ② ③ (1) - Pre-tensioner (3) - Main tensioner (2) - Additional tensioner Operating Instructions 868-M - 01.0 - 12/2020...
  • Page 51 To set the length of the initial thread: Shorter initial thread Turn the adjusting wheel (4) of the pre-tensioner (1) clockwise. Longer initial thread Turn the adjusting wheel (4) of the pre-tensioner (1) counter- clockwise. Operating Instructions 868-M - 01.0 - 12/2020...
  • Page 52 The switchable additional tensioner (2) can be used to quickly adjust the needle thread tension, e.g. for thickened seams. Proper setting The additional tensioner (2) must be set lower than the main tensioner (3). Operating Instructions 868-M - 01.0 - 12/2020...

  • Page 53: Opening The Needle Thread Tension

    Push the lever (2) on the handle (1) to the left. Information On machines with thread cutter, the additional tensioner is switched on and off with the press of a button housed in the push button panel. Operating Instructions 868-M - 01.0 - 12/2020...

  • Page 54: Setting The Hook Thread Tension

    The hook thread tension is adjusted using the tension spring (2). To set the hook thread tension: Increasing the hook thread tension Turn the adjusting screw (1) clockwise. Reducing the hook thread tension Turn the adjusting screw (1) counterclockwise. Operating Instructions 868-M - 01.0 - 12/2020...

  • Page 55: Setting The Needle Thread Regulator

    Loosen the screw (3). • To increase the tension: Slide the needle thread regulator (1) to the right • To reduce the tension: Slide the needle thread regulator (1) to the left Tighten the screw (3). Operating Instructions 868-M - 01.0 - 12/2020...

  • Page 56: In 2-Needle Machines

    To set the needle thread regulator for the right needle thread: Loosen the screw (3). • To increase the tension: Slide the needle thread regulator (1) to the right. • To reduce the tension: Slide the needle thread regulator (1) to the left. Operating Instructions 868-M - 01.0 - 12/2020...
  • Page 57 When the largest thread quantity is required, the thread tension spring (2) must be pulled approx. 0.5 mm up from its lower end position. This occurs when the needle thread loop passes the maximum hook diameter. Operating Instructions 868-M - 01.0 - 12/2020...

  • Page 58: Locking The Sewing Feet At Top Dead Center

    Swivel the lever (1) up.  The lock is canceled. Information The sewing foot can also be lifted pneumatically using the pedal or the knee button. The lever (1) will then swivel back up automatically. Operating Instructions 868-M - 01.0 - 12/2020...

  • Page 59: Sewing Foot Stroke

    Follow the specified maximum speeds: Sewing foot stroke Maximum speed Stitch length Subclass Adjusting wheel range [mm] [min position 868-190322-M 1-2, 5 2500 2400 868-290322-M 2200 2000 868-190020-M 1800 1600 868-290020-M 8-12 1600 Operating Instructions 868-M - 01.0 - 12/2020...

  • Page 60: Setting The Sewing Foot Stroke

    On machines with only 1 adjusting wheel, the highest stroke of 9 mm is automatically activated as the increased sewing foot stroke by pressing a button housed in the push button panel. Operating Instructions 868-M - 01.0 - 12/2020...
  • Page 61 CLASSIC machines only) To set the sewing foot stroke: Increasing the sewing foot stroke Turn the adjusting wheel (1)/(2) clockwise. Reducing the sewing foot stroke Turn the adjusting wheel (1)/(2) counterclockwise. Operating Instructions 868-M - 01.0 - 12/2020...

  • Page 62: Quick Stroke Adjustment Via Knee Button

    Information The knee button (2) can also be assigned functions other than the activation of the sewing foot stroke in push-to-run and hold-to-run mode ( p. 87). Operating Instructions 868-M - 01.0 - 12/2020...

  • Page 63: Lifting The Sewing Feet

    To lift the sewing feet mechanically using the knee lever (1): Use your right knee to push the knee lever (1) to the right.  The sewing feet remain open while the knee lever (1) is pushed to the right. Operating Instructions 868-M - 01.0 - 12/2020...

  • Page 64: Electropneumatic Lifting With The Pedal

    The sewing feet remain up as long as the pedal (1) is pressed back in position -1. Press the pedal (1) fully back to position -2.  The thread cutter is activated, and the sewing feet are raised. Operating Instructions 868-M - 01.0 - 12/2020...

  • Page 65: Setting The Sewing Foot Pressure

    The sewing foot pressure is set using the adjusting wheel (1). To set the sewing foot pressure: Increasing the sewing foot pressure Turn the adjusting wheel (1) clockwise. Reducing the sewing foot pressure Turn the adjusting wheel (1) counterclockwise. Operating Instructions 868-M - 01.0 - 12/2020...

  • Page 66: Buttons On The Push Button Panel

    If start/ end bartacks are off, pressing the button sews the next bartack. For the general setting required for sewing start and end bartacks, refer to the  Instructions for use DAC basic/classic. Operating Instructions 868-M - 01.0 - 12/2020...
  • Page 67 This button is used to activate the left needle bar. This button is used to activate the right needle bar. Information The number of buttons and their functions vary with the equipment of the machine. Operating Instructions 868-M - 01.0 - 12/2020...

  • Page 68: Switching On And Off The Function Of A Button

    The additional button (3) is only found on 2-needle machines with switchable needle bars. You can use the buttons L and R to select if the left or the right needle bar is supposed to be activated (e.g. to sew around corners) Operating Instructions 868-M - 01.0 - 12/2020...

  • Page 69: Assigning Functions To The Favorite Button

    Turn all screws (2) to their initial position (3) so that the slots of the screws are horizontal. Turn the screw (2) under the desired button 90° so that the slot is vertical (4). Operating Instructions 868-M - 01.0 - 12/2020...

  • Page 70: Leds On The Machine Arm

    When the right LED is on, the remaining thread monitor signals that the bobbin in the right hook is almost empty. When on, the LED signals that the machine is switched on and not powered off. Operating Instructions 868-M - 01.0 - 12/2020...

  • Page 71: Remaining Thread Monitor

    Proceed as follows when the remaining thread monitor signals the end of the hook thread: Finish the seam you started.  The hook thread quantity in the supply groove (2) of the bobbin is usually sufficient to do so. Operating Instructions 868-M - 01.0 - 12/2020...
  • Page 72 Changing the bobbin ( p. 44).  You can start sewing a new seam. Take the remaining thread off the bobbin you removed. If necessary, wind a new hook thread onto the empty bobbin ( p. 41). Operating Instructions 868-M - 01.0 - 12/2020...
  • Page 73 ( p. 97). To clean the remaining thread monitor: Switch off the machine. Clean the lenses of the light barrier using compressed air.  The machine can be switched back on. Operating Instructions 868-M - 01.0 - 12/2020...

  • Page 74: Sewing Backwards With The Stitch Adjustment Lever

    Information To sew bartacks manually, press the stitch adjustment lever (1) down. The machine will sew backwards for as long as you keep down the stitch adjustment lever (1). Operating Instructions 868-M - 01.0 - 12/2020...

  • Page 75: Stitch Length

    The stitch length at adjusting wheel (2) must NOT be greater than the stitch length at adjusting wheel (3). Fig. 49: Setting the stitch length ① ② ③ (1) - Marking (3) - Adjusting wheel (2) - Adjusting wheel Operating Instructions 868-M - 01.0 - 12/2020...
  • Page 76 Setting the stitch length on the adjusting wheel (3) Turn the adjusting wheel (3) clockwise until you reach the desired stitch length. The marking (1) on the left of the adjusting wheel indicates the stitch length selected. Operating Instructions 868-M - 01.0 - 12/2020...

  • Page 77: Sewing With 2 Stitch Lengths

    These can be used to sew two different stitch lengths and can be activated with a press of button (1). The stitch lengths are set using the adjusting wheels (2) and (3). Operating Instructions 868-M - 01.0 - 12/2020...

  • Page 78: Removing Blocking Of The Adjusting Wheels

    (1). Set the adjusting wheels (1) again ( p. 73). Insert a 3 mm hex key through the access holes (2) and tighten the blocking screws for the adjusting wheels (1). Operating Instructions 868-M - 01.0 - 12/2020...

  • Page 79: Additional Equipment Seam Middle Guide

    The seam middle guide can be activated/deactivated using a button on the push button panel ( p. 64). There are 2 versions of the seam middle guide: Fig. 52: Additional equipment seam middle guide (1) ① (1) - Seam middle guide Operating Instructions 868-M - 01.0 - 12/2020...
  • Page 80 Fig. 53: Additional equipment seam middle guide (2) ② (2) - Seam middle guide To keep the seam middle guide (1)/(2) from leaving marks or damaging the sewing material, the maximum operating pressure must not exceed 3 bar. Operating Instructions 868-M - 01.0 - 12/2020...
  • Page 81 To reduce the contact pressure of the seam middle guide (1)/(2): Pull the pressure controller (4) up. Turn the pressure controller (4) counterclockwise until the pressure gage (3) indicates the proper setting. Push the pressure controller (4) down. Operating Instructions 868-M - 01.0 - 12/2020...

  • Page 82: Sewing

    Positioning the sewing material To position the sewing material: Press the pedal (5) halfway back to position -1:  The sewing feet are lifted. Push the sewing material into the initial position. Operating Instructions 868-M - 01.0 - 12/2020...
  • Page 83 ( p. 75). Increasing the thread tension To increase the thread tension: Switch on the additional tensioner using the quick function button ( p. 51). Operating Instructions 868-M - 01.0 - 12/2020...
  • Page 84 Press the pedal (5) fully back to position -2:  The machine sews the end bartack, and the thread cutter cuts the thread. The machine stops, and needle and sewing feet are up. Remove the sewing material. Operating Instructions 868-M - 01.0 - 12/2020...

  • Page 85: Sewing With The Machine

    0. The machine is ready for operation. Press the pedal back to position -1.  Lift the sewing feet. Place the sewing material at the appropriate position above the throat plate. Operating Instructions 868-M - 01.0 - 12/2020...
  • Page 86 (1) - Button (sewing in reverse) (3) - Button (activate auxiliary thread (2) - Button (switching over the stitch tension) length) Fig. 57: Sewing with the machine (2) ④ (4) - Stitch adjustment lever Operating Instructions 868-M - 01.0 - 12/2020...
  • Page 87 (5) once or press it and hold it down ( p. 60). 13. To switch the increased sewing foot stroke off, press the knee button (5) again stop holding it down. Operating Instructions 868-M - 01.0 - 12/2020...
  • Page 88  If activated, the machine will sew the end bartack. The thread is cut off. The machine stops in the 2 position. The needle and the sewing feet are up. 15. Remove the sewing material. Operating Instructions 868-M - 01.0 - 12/2020...

  • Page 89: Programming

    Using the control panel you can: • Use groups of buttons to select machine functions • Read service and error messages Information This chapter describes the machine-specific functions of the OP1000 control panel. Operating Instructions 868-M - 01.0 - 12/2020...

  • Page 90: Buttons On The Control Panel

    (7) - Display (4) - Programming button group OP1000 buttons and functions Button Function Thread button group Start bartack • Sets the start bartack Multiple start bartack • Sets the multiple start bartack Operating Instructions 868-M - 01.0 - 12/2020...
  • Page 91 • Activates or deactivates the sewing stop sewing foot lift after sewing stops Soft start • Activates or deactivates the soft start Speed • Reduces the motor speed Function button • Activates or deactivates any stored function Operating Instructions 868-M - 01.0 - 12/2020...
  • Page 92 • Increases parameter • Selects subprogram • Increases parameter • Selects subprogram • Calls parameter or saves it • Starts or ends the parameter mode • Decreases parameter • Changes user level • Selects subprogram Operating Instructions 868-M - 01.0 - 12/2020...
  • Page 93 • 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 Operating Instructions 868-M - 01.0 - 12/2020...

  • Page 94: Assigning Functions To Buttons On The Push Button Panel

     The control panel shows the value currently set for the button. Use +/- to enter the desired value ( Parameter list 868). Confirm with Press the button.  The machine is ready to sew again. Operating Instructions 868-M - 01.0 - 12/2020...

  • Page 95: Assigning A Function To The Knee Button

    Set the toggle switch (1) to the desired position (1 or 0). If the toggle switch (1) is, for instance, set to the bottom position, the new function is saved to the 0 position. Operating Instructions 868-M - 01.0 - 12/2020...
  • Page 96 The display shows a numerical value. Use the buttons + or - to set the numerical value to the desired value associated with the new function ( Parameter list 868). Confirm with Operating Instructions 868-M - 01.0 - 12/2020...

  • Page 97: Maintenance

    Advanced maintenance work may only be carried out by qualified specialists ( Service Instructions). Operating Instructions 868-M - 01.0 - 12/2020...
  • Page 98 Servicing the pneumatic system  Setting the operating pressure  Check the water level in the pressure controller  Draining the water condensation  Cleaning the filter element  Check the tightness of the system Operating Instructions 868-M - 01.0 - 12/2020...

  • Page 99: Cleaning

    Clean the machine as described. If very fluffy sewing material is being sewn, the machine must be cleaned more frequently. NOTICE Property damage from solvent-based cleaners! Solvent-based cleaners will damage paintwork. Use only solvent-free substances for cleaning. Operating Instructions 868-M - 01.0 - 12/2020...
  • Page 100 • Area around the needle (1) • Area around the hook (2) • Area under the throat plate (3) • Sensor of the remaining thread monitor • Cutter on the winder for the hook thread (4) Operating Instructions 868-M - 01.0 - 12/2020...

  • Page 101: Lubricating

    Carefully collect up used oil. Dispose of used oil and oily machine parts in accordance with national regulations. The machine is equipped with a central oil-wick lubrication system. The bearings are supplied from the oil reservoir. Operating Instructions 868-M - 01.0 - 12/2020...
  • Page 102 • 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 Operating Instructions 868-M - 01.0 - 12/2020...

  • Page 103: Checking The Oil Level

    (2). Important The lamp behind the inspection glass will not go out until the oil has been topped off and the machine was switched off and back on again ( p. 20). Operating Instructions 868-M - 01.0 - 12/2020...

  • Page 104: Setting The Hook Lubrication

    10 seconds with the sewing feet lifted and at a high speed.  The blotting paper will show a thin strip of oil when sewing is complete. Fig. 67: Setting the hook lubrication ① (1) - Screw Operating Instructions 868-M - 01.0 - 12/2020...
  • Page 105 Sew for several minutes before you check the setting again. Information The right and the left hook are designed in exactly the same way, but they are mirror images of each other. Operating Instructions 868-M - 01.0 - 12/2020...

  • Page 106: Servicing The Pneumatic System

    The operating pressure cannot deviate by more than ± 0.5 bar. Check the operating pressure on a daily basis. Fig. 68: Setting the operating pressure ① ② (1) - Pressure controller (2) - Pressure gage Operating Instructions 868-M - 01.0 - 12/2020...
  • Page 107 Pull the pressure controller (1) up. Turn the pressure controller until the pressure gage (2) indicates the proper setting: • Increase pressure = turn clockwise • Reduce pressure = turn counterclockwise Push the pressure controller (1) down. Operating Instructions 868-M - 01.0 - 12/2020...

  • Page 108: Draining The Water Condensation

    To drain water condensation: Disconnect the machine from the compressed air supply. Place the collection tray under the drain screw (3). Loosen the drain screw (3) completely. Allow water to drain into the collection tray. Operating Instructions 868-M - 01.0 - 12/2020...

  • Page 109: Cleaning The Filter Element

    Disconnect the machine from the compressed air supply. Drain the water condensation ( p. 106). Loosen the water separator (2). Loosen the filter element (1). Blow out the filter element (1) using the compressed air gun. Operating Instructions 868-M - 01.0 - 12/2020...

  • Page 110: Parts List

    Tighten the drain screw (3). 10. Connect the machine to the compressed air supply. Parts list A parts list can be ordered from Dürkopp Adler. Or visit our website for further information at: www.duerkopp-adler.com Operating Instructions 868-M - 01.0 - 12/2020...

  • Page 111: Setup

    • Lashing straps and wooden blocks from the machine head • If applicable, lashing straps and wooden blocks from the tabletop and the stand • If applicable, restrain block and straps from the sewing motor • All pieces of Styrofoam and cardboard Operating Instructions 868-M - 01.0 - 12/2020...

  • Page 112: Assembling The Stand

    Assemble the stand as shown in the figure. Important: Turn the adjusting screw (1) so that the stand has even contact with the ground. Information The working height can be set at the stand ( p. 122). Operating Instructions 868-M - 01.0 - 12/2020...

  • Page 113: Assembling The Control

    Screw the control (2) onto the 4 screw holders (3) under the tabletop. Clamp the power cable of the control (2) into the strain relief mechanism (1). Screw the strain relief mechanism (1) in place under the tabletop using 2 screws. Operating Instructions 868-M - 01.0 - 12/2020...

  • Page 114: Completing The Tabletop

    Setup Completing the tabletop To complete the tabletop, you must assemble the tilt protection device, the drawer, the oil pan, the reel stand and the protection parts. Fig. 73: Completing the tabletop (1) Operating Instructions 868-M - 01.0 - 12/2020...
  • Page 115 Assemble the drawer (1) on the left under the tabletop. Assemble the oil pan (2) under the tabletop.  The stand must be assembled between the drawer (1) and the oil pan (2). Operating Instructions 868-M - 01.0 - 12/2020...
  • Page 116 Insert the rubber corners (5) into the front corners in the tabletop cutout. Insert the lower hinge parts (3) into the hinge slots in the tabletop cutout on the rear left and right. Operating Instructions 868-M - 01.0 - 12/2020...
  • Page 117 (7) - Plug To assemble the tilt protection device: Assemble the tilt protection device (6) in the designated slot of the tabletop. Screw the plug (7) into the designated slot of the tabletop. Operating Instructions 868-M - 01.0 - 12/2020...
  • Page 118 Screw in a nut (8) until you reach the end of the thread (10). Insert the reel stand tube (11) through the washer (9) and into the hole in the tabletop. Slip the 2 washer (9) from the bottom onto the thread (10). Operating Instructions 868-M - 01.0 - 12/2020...

  • Page 119: Assembling The Pedal And Setpoint Device

    Fit the pedal (1) on the cross strut (2) and align it in such a way that the middle of the pedal is under the needle. Tighten the pedal (1) on the cross strut (2). Operating Instructions 868-M - 01.0 - 12/2020...
  • Page 120 Attach the pedal rod (7) with the ball joints (5) to the setpoint device (4) and to the pedal (1). Slightly loosen the screw (6). Fig. 81: Assembling the pedal and setpoint device (3) 10° ① Operating Instructions 868-M - 01.0 - 12/2020...

  • Page 121: Inserting The Machine Head

    Cable may sustain damage and impair the operation of the machine. Always lay the cables so as not to create any chafing or pinching points. Fig. 82: Inserting the machine head (1) ② ① (1) - Hinge (2) - Machine head Operating Instructions 868-M - 01.0 - 12/2020...
  • Page 122 Fig. 83: Inserting the machine head (2) Guide the cables through the tabletop with great care so as not to kink or pinch them. Insert the machine head (2) vertically into the tabletop cutout. Operating Instructions 868-M - 01.0 - 12/2020...
  • Page 123 Use the tilt protection device (4) to secure the machine head at the right hinge (1). Fig. 85: Inserting the machine head (5) ⑤ (5) - Tilt protection device The machine head is secured further with the tilt protection device (5). Operating Instructions 868-M - 01.0 - 12/2020...

  • Page 124: Setting The Working Height

    Adjust the working height to the body height of the person who will operate the machine. Fig. 86: Assembling the stand ① (1) - Screw Operating Instructions 868-M - 01.0 - 12/2020...

  • Page 125: Setting The Pedal

    To set the pedal properly: Loosen the screw (1). Set the pedal (2) to the proper position on the cross strut (3) ( p. 117). Tighten the screw (1). Operating Instructions 868-M - 01.0 - 12/2020...

  • Page 126: Assembling The Control Panel

    Guide the connecting cable (3) behind covers (4) and (5) and down through the tabletop cutout towards the control. Assemble cover (4) and cover (5). Make sure not to damage the connecting cable (3) or the other cables. Operating Instructions 868-M - 01.0 - 12/2020...

  • Page 127: Assembling The Knee Lever / Knee Button

    ③ (1) - Oil pan (3) - Knee lever (2) - Rod (4) - Connecting piece Fig. 90: Assembling the mechanical knee lever (2) ⑤ ⑥ (5) - Transmission rod (6) - Screw Operating Instructions 868-M - 01.0 - 12/2020...

  • Page 128: Assembling The Electric Knee Button

    Guide the connecting cable (2) to the back between the oil pan and the control. Insert the plug (3) of the connecting cable (2) into the socket of the control. Operating Instructions 868-M - 01.0 - 12/2020...

  • Page 129: Assembling The Oil Extraction Line

    Slip the end of the oil extraction line onto the adapter on the cover (3). Clip the oil extraction line (4) into the tube holder (2). Screw the cover (5) to the base plate. Operating Instructions 868-M - 01.0 - 12/2020...

  • Page 130: Electrical Connection

    Property damage may occur! Crushing and cable breakage possible. When laying the grounding wire, ensure that the wire is not pinched. Fig. 94: Establishing equipotential bonding ② ① (1) - Grounding wire (2) - Tab connector Operating Instructions 868-M - 01.0 - 12/2020...

  • Page 131: Pneumatic Connection

    The pneumatic system of the machine and of the additional equip- ment must be supplied with dry and oil-free compressed air. The supply pressure must lie between 8 and 10 bar. Operating Instructions 868-M - 01.0 - 12/2020...

  • Page 132: Assembling The Compressed Air Maintenance Unit

    Refer to the Technical data ( p. 149) chapter for the permissi- ble operating pressure. The operating pressure cannot deviate by more than ± 0.5 bar. Fig. 95: Setting the operating pressure ① ② (1) - Pressure controller (2) - Pressure gage Operating Instructions 868-M - 01.0 - 12/2020...

  • Page 133: Checking The Lubrication

    (1). If this is the case, top off oil ( p. 101). 7.17 Performing a test run When setup is complete, perform a test run to check the function- ality of the machine. Operating Instructions 868-M - 01.0 - 12/2020...
  • Page 134 Setup Operating Instructions 868-M - 01.0 - 12/2020...

  • Page 135: Decommissioning

    Remove residual oil from the oil pan using a cloth. Cover the control panel to protect it from soiling. Cover the control to protect it from soiling. Cover the entire machine if possible to protect it from contam- ination and damage. Operating Instructions 868-M - 01.0 - 12/2020...
  • Page 136 Decommissioning Operating Instructions 868-M - 01.0 - 12/2020...

  • Page 137: 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. Operating Instructions 868-M - 01.0 - 12/2020...
  • Page 138 Disposal Operating Instructions 868-M - 01.0 - 12/2020...

  • Page 139: Troubleshooting

    Fax +49 (0) 521 925 2594 Email: service@duerkopp-adler.com Internet: www.duerkopp-adler.com 10.2 Messages of the software Please contact customer service if an error occurs that is not described here. Do not attempt to correct the error yourself. Operating Instructions 868-M - 01.0 - 12/2020...

  • Page 140: Information Messages

    • Check connection cables position not found • Check stepper motor 1 for stiff movement 2220 DA stepper card 2 not • Check connection cables responding • Check LEDs of DACextension box • Software update Operating Instructions 868-M - 01.0 - 12/2020...
  • Page 141 3217 Remaining thread monitor • Change the right bobbin right 3218 Remaining thread monitor • Change the left and right left and right bobbin 3223 Skip stitch detected 3224 Bobbin failed to rotate Operating Instructions 868-M - 01.0 - 12/2020...
  • Page 142 Internal EEprom defective • Replace the control and external data not valid (emergency operating features only) 6367 Internal EEprom defective • Replace the control and external EEprom not connected (emergency operating features only) Operating Instructions 868-M - 01.0 - 12/2020...
  • Page 143 DAC basic will remain available) 7803 Communication error (DAC • Restart of the control classic only; only the • Software update functions of the DAC basic • Replace the control will remain available) Operating Instructions 868-M - 01.0 - 12/2020...

  • Page 144: Error Messages

    • Replace the encoder exceeded • Perform reset • Check class (t 51 04) 1007 Error Error in the reference run • Replace the encoder • Eliminate stiff movement in the sewing machine Operating Instructions 868-M - 01.0 - 12/2020...
  • Page 145 DA stepper card 1 • Check reference reference run timeout sensor 2103 Error DA stepper card 1 step • Check for stiff losses movement 2155 Error DA stepper card 1 • Check for stiff overload movement Operating Instructions 868-M - 01.0 - 12/2020...
  • Page 146 24 V short circuit 3106 Error U24 V (I T) overload • One or several magnets defective 3107 Error Pedal not connected • Connect analog pedal 3109 Warning Operation lock • Check tilt sensor on machine Operating Instructions 868-M - 01.0 - 12/2020...
  • Page 147 8405 • Machine ID reset • Replace the control 8406 Error Checksum error • Software update • Replace the control 8501 Error Software protection • Always use the DA tool for software updates Operating Instructions 868-M - 01.0 - 12/2020...

  • Page 148: Errors In Sewing Process

     p. 119 incorrectly Thread tensions are too Check thread tensions  p. 47 tight Throat plate, hook or spread Have parts reworked by have been damaged by the qualified specialists  p. 137 needle Operating Instructions 868-M - 01.0 - 12/2020...
  • Page 149 Needle thread and hook Check threading path  p. 28 thread have not been threaded correctly Needle Needle thickness is Use recommended needle thickness  p. 149 breakage unsuitable for the sewing material or the thread Operating Instructions 868-M - 01.0 - 12/2020...
  • Page 150 Troubleshooting Operating Instructions 868-M - 01.0 - 12/2020...

  • Page 151: Technical Data

    • for heavy sewing material 140-180 Thread strength [Nm] 80/3-10/3 Stitch length forwards/backwards [mm] 12/12 Number of adjustable stitch lengths 2500 Maximum speed [min 2500 Speed on delivery [min Maximum stroke height (only with reversing mechanism) [mm] Operating Instructions 868-M - 01.0 - 12/2020...

  • Page 152: Permissible Maximum Speeds

    NOT exceed the permissible maximum speeds: Sewing foot stroke Maximum speed Stitch length Subclass Adjusting wheel range [mm] [min position 868-190322-M 1-2, 5 2500 2400 868-290322-M 2200 2000 868-190020-M 1800 1600 868-290020-M 8-12 1600 Operating Instructions 868-M - 01.0 - 12/2020...

  • Page 153: Characteristics

    3-63 mm • The possible needle spacing for the vertical XXL hook with and without thread cutter is 3-56 mm • Subclass 868-490322-M is equipped with switchable needle bars Operating Instructions 868-M - 01.0 - 12/2020...
  • Page 154 Technical data Operating Instructions 868-M - 01.0 - 12/2020...

  • Page 155: Appendix

    Appendix 12 Appendix Fig. 97: Wiring diagram (1) Operating Instructions 868-M - 01.0 - 12/2020...
  • Page 156 Appendix Fig. 98: Wiring diagram (2) Operating Instructions 868-M - 01.0 - 12/2020...
  • Page 157 Appendix Fig. 99: Wiring diagram (3) Operating Instructions 868-M - 01.0 - 12/2020...
  • Page 158 Appendix Fig. 100: Wiring diagram (4) Operating Instructions 868-M - 01.0 - 12/2020...
  • Page 159 Appendix Fig. 101: Wiring diagram (5) Operating Instructions 868-M - 01.0 - 12/2020...
  • Page 160 Appendix Fig. 102: Wiring diagram (6) Operating Instructions 868-M - 01.0 - 12/2020...
  • Page 161 Appendix Fig. 103: Wiring diagram (7) Operating Instructions 868-M - 01.0 - 12/2020...
  • Page 162 Appendix Fig. 104: Tabletop drawing (1) Operating Instructions 868-M - 01.0 - 12/2020...
  • Page 163 Appendix Fig. 105: Tabletop drawing (2) Operating Instructions 868-M - 01.0 - 12/2020...
  • Page 164 Appendix Fig. 106: Tabletop drawing (3) Operating Instructions 868-M - 01.0 - 12/2020...
  • Page 165 Appendix Fig. 107: Tabletop drawing (4) Operating Instructions 868-M - 01.0 - 12/2020...
  • Page 166 Appendix Operating Instructions 868-M - 01.0 - 12/2020...
  • Page 168 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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