Duerkopp Adler 869-M PREMIUM Operating Instructions Manual
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Duerkopp Adler 869-M PREMIUM Operating Instructions Manual

Duerkopp Adler 869-M PREMIUM Operating Instructions Manual

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869-M PREMIUM
Operating Instructions

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Summary of Contents for Duerkopp Adler 869-M PREMIUM

  • Page 1 869-M PREMIUM Operating 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 2018...

  • Page 3: Table Of Contents

    4.13.2 Assigning a function to the favorite button .......... 51 4.14 Sewing....................52 Programming ..................55 Control panel OP3000 ................. 55 Switching on the machine ..............57 Software operating modes ..............59 Operating Instructions 869-M PREMIUM - 02.0 - 01/2018...
  • Page 4 Setting the operating pressure ............113 6.3.2 Draining the water condensation ............114 6.3.3 Cleaning the filter element..............116 Parts list..................... 117 Setup ....................119 Checking the scope of delivery ............119 Operating Instructions 869-M PREMIUM - 02.0 - 01/2018...
  • Page 5 Customer Service ................143 10.2 Messages of the software ..............144 10.2.1 Information messages ............... 144 10.2.2 Error messages ................. 148 10.3 Errors in sewing process ..............155 Technical data ................. 157 Appendix ..................159 Operating Instructions 869-M PREMIUM - 02.0 - 01/2018...
  • Page 6 Table of Contents Operating Instructions 869-M PREMIUM - 02.0 - 01/2018...

  • Page 7: About These Instructions

    About these instructions About these instructions These instructions have been prepared with utmost care. They contain information and notes intended to ensure long-term and reliable operation. Should you notice any discrepancies or if you have improvement requests, then we would be glad to receive your feedback through Customer Service (...

  • Page 8: Representation Conventions - Symbols And Characters

    About these instructions Representation conventions – symbols and characters Various information in these instructions is represented or high- lighted by the following characters in order to facilitate easy and quick understanding: Proper setting Specifies proper setting. Disturbances Specifies the disturbances that can occur from an incorrect setting. Cover Specifies which covers must be disassembled in order to access the components to be set.

  • Page 9: Other Documents

    About these instructions Information Additional information, e.g. on alternative operating options. Order Specifies the work to be performed before or after a setting. References  Reference to another section in these instructions. Safety Important warnings for the user of the machine are specifically marked.

  • Page 10: Liability

    About these instructions Liability All information and notes in these instructions have been compiled in accordance with the latest technology and the applicable stan- dards and regulations. Dürkopp Adler cannot be held liable for any damage resulting from: • Breakage and damage during transport •...

  • Page 11: Safety

    Safety Safety This chapter contains basic information for your safety. Read the instructions carefully before setting up or operating the machine. Make sure to follow the information included in the safety instruc- tions. Failure to do so can result in serious injury and property damage.

  • Page 12: Signal Words And Symbols Used In Warnings

    Safety All the warnings and safety signs on the machine must always be in legible condition. Do not remove! Missing or damaged warnings and safety signs must be replaced immediately. Requirements Only qualified specialists may: to be met by • set up the machine the personnel •...
  • Page 13 Safety CAUTION (with hazard symbol) If ignored, moderate or minor injury can result CAUTION (with hazard symbol) 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...
  • Page 14 Safety Examples Examples of the layout of warnings in the text: DANGER 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 will result in serious injury or even death if ignored. WARNING Type and source of danger! Consequences of non-compliance.
  • Page 15 Safety 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. CAUTION Type and source of danger! Consequences of non-compliance.
  • Page 16 Safety Operating Instructions 868-M PREMIUM - 02.0 - 01/2018...

  • Page 17: Machine Description

    Machine description Machine description Components of the machine Fig. 1: Components of the machine ⑦ ⑥ ① ⑤ ④ ② ③ (1) - Programmable (4) - Oil level indicator thread tension (5) - Winder (2) - Push buttons (6) - Electronic handwheel (3) - Stitch adjustment lever (7) - Control panel OP3000 Operating Instructions 868-M PREMIUM - 02.0 - 01/2018...

  • Page 18: Proper Use

    Machine description Proper use WARNING Risk of injury from live, moving and cutting parts as well as from sharp parts! Improper use can result in electric shock, crushing, cutting and punctures. Follow all instructions provided. NOTICE Non-observance will lead to property damage! Improper use can result in material damage at the machine.

  • 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 PREMIUM - 02.0 - 01/2018...
  • Page 20 Machine description Operating Instructions 868-M PREMIUM - 02.0 - 01/2018...

  • Page 21: Operation

    Operation Operation The operating sequence consists of several different steps. Fault-free operation is necessary in order to achieve a good sewing result. Preparing the machine for operation WARNING Risk of injury from moving, cutting and sharp parts! Crushing, cutting and punctures are possible. If possible, make preparations only when the machine is switched off.

  • Page 22: Switching On And Off The Machine

    Operation Switching on and off the machine Fig. 2: Switching on and off the machine ① ② ③ (1) - Indicator LED (3) - POWER LED (2) - Switch Switching on the machine To switch on the machine: Press the switch (2) to the I position. ...

  • Page 23: Switching On And Off The Sewing Lamp

    Operation Switching on and off the sewing lamp The sewing lamp switches on and off independent of the main switch. Fig. 3: Switching on and off the Sewing lamp ① ③ ② (1) - Switch (3) - Switch (2) - Button Switching on the dimmable sewing lamp To switch on the dimmable sewing lamp: Press the switch (3) to the I position.

  • Page 24: Inserting/Changing The Needle

    Operation Inserting/changing the needle CAUTION Risk of injury from sharp parts! Punctures possible. Switch off the machine before you insert or change the needle. NOTICE Property damage may occur! There is a risk of machine damage, needle breakage or thread breakage if the distance between needle and hook tip is incorrect.
  • Page 25 Operation Loosen the screw (2). Pull the needle out towards the bottom. Insert the new needle into the hole in the needle bar (1) until it reaches the end stop. Important Align the needle in such a way that the groove (3) faces the hook (4). Tighten the screw (2).

  • Page 26: In 2-Needle Machines

    Operation 4.4.1 In 2-needle machines Fig. 5: Inserting/changing the needle (2) ① ④ ② ② ③ ③ (1) - Needle bar (3) - Groove (2) - Screw (4) - Needle holder To change the needle in a 2-needle machine: Turn the handwheel until the needle bar (1) has reached the upper end position.
  • Page 27 Operation Order Always adjust the clearance between the hook and the needle after changing to a different needle thickness ( Service Instructions). Disturbance An incorrect hook distance can cause the following disturbances: • Changing to a thinner needle: • Missing stitches •...

  • Page 28: Threading The Needle Thread

    Operation Threading the needle thread WARNING Risk of injury from needle tip and moving parts! Puncture, cutting and crushing possible. Turn off the machine before threading the thread. 4.5.1 In 1-needle machines Fig. 6: Threading the needle thread (1-needle machine) (1) ①...
  • Page 29 Operation The unwinding bracket must stand directly above the thread reel. Feed the thread from the rear to the front through the thread guide (2) on the unwinding bracket. Use compressed air to blow the thread through the hose guide (1). Information To blow the thread through the hose guide (1) with the help of compressed air, position the compressed air gun together with...
  • Page 30 Operation Fig. 8: Threading the needle thread (1-needle machine) (3) ⑯ ⑪ 1 2 3 4 ⑫ ⑮ ⑬ ⑭ (11) - Hook (14) - Thread guide (12) - Upper thread guide (15) - Needle thread regulator (13) - Lower thread guide (16) - Thread lever 10.
  • Page 31 Operation For machines with thread clamp (optional) 15. Insert the thread through the left hole of the guide above the thread clamp. 16. Insert the thread through the left hole of the guide below the thread clamp. Fig. 9: Thread clamp 17.

  • Page 32: In 2-Needle Machines

    Operation For machines with thread cutter 20. Pull the thread through the needle eye until the loose thread end has a length of approx. 4 cm with the thread lever (16) at the highest position. Important: Check the thread length. If the loose thread end is too long, the thread may be caught by the hook and cause a disturbance.
  • Page 33 Operation The unwinding bracket (3) must stand directly above the thread reels. Feed the right thread from the rear to the front to the right hose guide (2). Feed the left thread from the rear to the front to the left hose guide (1).
  • Page 34 Operation Threading the right needle thread at the tensioning plate Fig. 11: Threading the needle thread (2-needle machine) (2) ⑩ ⑨ ④ ⑤ ⑥ ⑦ ⑧ (4) - Spring tip (9) - Pre-tensioner (5) - Thread tension spring (right needle thread) (6) - Tightening lever (10) - Tensioner (7) - Thread guide (right needle thread)
  • Page 35 Operation Threading the left needle thread at the tensioning plate Fig. 12: Threading the needle thread (2-needle machine) (3) ⑭ ⑬ ⑪ ⑫ (11) - Thread guide (left needle thread) (13) - Pre-tensioner (left needle thread) (12) - Tensioner (left needle thread) (14) - Tensioner (left needle thread) 11.
  • Page 36 Operation Threading the needle thread at the needle thread regulator Fig. 13: Threading the needle thread (2-needle machine) (4) ⑮ ⑯ ⑰ (15) - Thread lever (not visible) (17) - Hook (16) - Needle thread regulator 17. Guide the right thread under the hook (17). 18.
  • Page 37 Operation Fig. 14: Threading the needle thread (2-needle machine) (5) ⑱ ⑲ (18) - Thread guide (19) - Thread clamp 23. Insert the right and the left thread through the upper thread guide (18). For machines with thread clamp (optional): 24.
  • Page 38 Operation Fig. 15: Threading the needle thread (2-needle machine) (6) ⑳ (20) - Thread guide 29. Insert the right thread through the right hole of the thread guide (20) on the needle bar. 30. Insert the left thread through the left hole of the thread guide (20) on the needle bar.

  • Page 39: Winding The Hook Thread

    Operation Winding the hook thread WARNING Risk of injury from needle tip and moving parts! Puncture, cutting and crushing possible. Turn off the machine before threading the thread. Fig. 16: Winding the hook thread (1) ① ② (1) - Thread guide (2) - Hose guide To wind the hook thread: Fit the thread reel on the reel stand.
  • Page 40 Operation Fig. 17: Winding the hook thread (2) ③ ⑥ ④ ⑤ (3) - Thread guide (5) - Pre-tensioner (4) - Thread guide (6) - Winder Feed the thread counterclockwise from the thread guide (4) around the pre-tensioner (5). Insert the thread in a wavelike manner through the 2 holes of the thread guide (3): from bottom to top through the left hole and from top to bottom through the right hole.
  • Page 41 Operation Information The hook thread is normally wound on when sewing is in progress. However, you can also wind on the hook thread without sewing, e. g. if you require a full bobbin in order to start sewing. For this purpose, use the winder mode in the softkey menu (...

  • Page 42: Changing The Bobbin

    Operation Changing the bobbin WARNING Risk of injury from needle tip and moving parts! Puncture, cutting and crushing possible. Turn off the machine before changing the bobbin. The procedure used to change the bobbin is the same for 1-needle machines and 2-needle machines. The only difference is that the hook into which the bobbin is inserted is turned by 180 degrees for the left and the right side.
  • Page 43 Operation Pull the hook thread under the tension spring (3). Feed the hook thread through the slot (1) and pull it approx. 3 cm further. Close the bobbin case retainer (6). Machines with automatic remaining thread monitor If the hook thread needs to be replaced, the LED indicator lamps (7) light up on the machine arm.

  • Page 44: Thread Tension

    Operation Thread tension Together with the hook thread tension, the needle thread tension influences the final seam pattern. With thin sewing material, excessive thread tension can lead to undesired gathering and thread breakage. Proper setting If the tension of needle thread and hook thread is identical, the thread interlacing lies in the middle of the sewing material.

  • Page 45: Setting The Hook Thread Tension

    Operation 4.8.2 Setting the hook thread tension WARNING Risk of injury from needle tip and moving parts! Puncture, cutting and crushing possible. Switch off the machine before setting the hook thread tension. Fig. 22: Setting the hook thread tension ① ②...

  • Page 46: Setting The Needle Thread Regulator

    Operation Setting the needle thread regulator WARNING Risk of injury from needle tip and moving parts! Puncture, cutting and crushing possible. Switch off the machine before setting the needle thread regulator. The needle thread regulator determines the tension applied to guide the needle thread around the hook.

  • Page 47: In 2-Needle Machines

    Operation 4.9.2 In 2-needle machines Fig. 24: Setting the needle thread regulator (2) ③ ④ ① ② (1) - Needle thread regulator (3) - Screw (left needle thread) (left needle thread) (4) - Screw (right needle thread) (2) - Needle thread regulator (right needle thread) To set the needle thread regulator for the right and the left needle thread in a 2-needle machine:...

  • Page 48: Lifting The Sewing Feet

    Operation Information When the largest thread quantity is required, the thread tension spring 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. 4.10 Lifting the sewing feet Fig.

  • Page 49: Sewing Backwards With The Stitch Adjustment Lever (Optional)

    Operation 4.11 Sewing backwards with the stitch adjustment lever (optional) The electronic stitch adjustment lever on the machine arm reduces the stitch length down to sewing backwards in the lower end position. Fig. 26: Sewing backwards with the stitch adjustment lever ①...

  • Page 50: Setting Quick Stroke Adjustment

    Operation 4.12 Setting quick stroke adjustment On machines with quick stroke adjustment the elevated sewing foot stroke is switched via the knee button. The toggle switch on the rear side of the knee button determines whether the elevated sewing foot stroke is switched on permanently or only while the knee button is pressed.

  • Page 51: Quick Functions On The Push Buttons

    Operation 4.13 Quick functions on the push buttons The machine has push buttons on the machine arm which can be used to activate specific functions while sewing. 4.13.1 Activating function buttons Fig. 28: Activating function buttons ② ③ ④ ⑤ ⑥...
  • Page 52 Operation Functions of the buttons Button Function Sewing backwards When this button is activated, the machine sews in reverse. Needle position When this button is activated, the needle moves to a specific position. This position is determined individually via the parameter settings.

  • Page 53: Assigning A Function To The Favorite Button

    Operation 4.13.2 Assigning a function to the favorite button You can assign one of the button functions to the favorite button. Select a function that you frequently use so that you can switch it on faster while sewing. Fig. 29: Assigning a function to the favorite button +/–...

  • Page 54: Sewing

    Operation 4.14 Sewing WARNING Risk of injury from the needle if sewing is started unintentionally! Punctures possible. Do not press the pedal when you fingers are in the area of the needle tip. Fig. 30: Sewing ① ② ③ ④ (1) - Position +1 (3) - Position -1 (2) - Position 0...
  • Page 55 Operation Condition Processes At seam beginning Start bartack • Press the pedal forwards (position +1) and keep it and sew there. Machine sews a start bartack (if specified). Afterwards, the machine continues to sew - with increasing speed the further forward the pedal is pressed.
  • Page 56 Operation Operating Instructions 868-M PREMIUM - 02.0 - 01/2018...

  • Page 57: Programming

    Programming Programming Control panel OP3000 Fig. 31: Control panel ① ② (1) - Softkey button (2) - Softkey menu button All settings in the software for the M-TYPE PREMIUM are per- formed using the OP3000 control panel. Button Function Numeric •...
  • Page 58 Programming Button Function Function is different for each menu. • Selection to the right • Selection to the left • Back one menu level • Increase the value • Scroll through the list (upwards) • Decrease the value • Scroll through the list (downwards) Softkey button The button can be assigned various functions as required, ...

  • Page 59: Switching On The Machine

    Programming Entering values Values can be entered using the ▲/▼ buttons or the numeric buttons. Information If a value is entered that is not within the specified value range, the software will automatically adopt the limit value which is closest to your entry from the value range.
  • Page 60 Programming Fig. 34: Display of the control/control panel software version ② ③ OP3000 V03.68 2014-11-27 2016-06-16 (2) - Software version of the OP3000 (3) - Control panel software  The machine performs a reference run: The display shows the program last used, or Manual mode. Fig.

  • Page 61: Software Operating Modes

    Programming Software operating modes The software of the 867-M PREMIUM has 3 available operating modes: • Manual mode (program 000) ( p. 60) Manual mode is the simplest operating mode. There are no programs/seam programs and no inputs for individual seam sections.

  • Page 62: Using Manual Mode

    Programming Using Manual mode Fig. 37: Parameters in manual mode 5 3.0 The following table shows the individual symbols of parameters on the display and the functions of the buttons on the control panel. For some parameters, the exact setting is described in more detail later in the chapter.
  • Page 63 Programming Symbol Meaning Needle thread tension Value range: 01 - 99 • Use ◄/► to select the needle thread tension parameter • Use ▲/▼ to change the needle thread tension Information If the values for the needle thread tension of the right and the left needle thread are not identical and changed jointly, the difference remains the same.
  • Page 64 Programming Symbol Meaning Other parameters • Use the OK button to go to the list • Use ▲/▼ to select the parameter • Use the OK button to go to the parameter settings More detailed description of parameters: • Speed (Max Speed) ( p. 67) •...
  • Page 65 Programming Symbol Meaning No function assigned No function assigned If the parameter FastMenuKeys was activated at the Technician level, the display of the control panel will show the symbols listed in the table. The buttons on the control panel located underneath can then be used to select the corresponding functions.

  • Page 66: Selecting The Quick Access Function (Softkey Menu)

    Programming 5.4.1 Selecting the quick access function (softkey menu) Here, you have quick access to functions during the sewing process. You can also assign a function to the softkey button. To select a quick access function: Press the softkey menu button.
  • Page 67 Programming Possible button assignment for the softkey button (Manual mode) Symbol Meaning Threading mode The needle bar moves to the defined position. The pedal is temporarily locked. Raise/lower sewing foot BEFORE the seam: Position of the sewing foot after thread cutting. IN the seam: Position of the sewing foot when sewing stops.
  • Page 68 Programming Symbol Meaning edge stop distance Moves to the position for the 2 edge stop distance. Edge stop reference run If the edge stop has lost its correct position due to an interruption, the reference run returns it to its starting position.

  • Page 69: Setting The Speed Parameter (Max Speed)

    Programming Symbol Meaning Thread clamp Function active or inactive. edge stop distance Moves to the position for the 2 edge stop distance. Edge stop reference run If the edge stop has lost its correct position due to an interruption, the reference run returns it to its starting position.

  • Page 70: Setting The Thread Clamp Parameter (Thread Clamp)

    Programming 5.4.4 Setting the Thread clamp parameter (Thread Clamp) If a thread clamp is present, this function can be activated or deactivated here. The thread clamp is closed for the 1 stitch of the seam to ensure that the needle thread lies on the underside of the sewing material.
  • Page 71 Programming Settings that are more complex and therefore require further explanation are described in more detail after the table. Menu items Setting option 1 Setting option 2 ON/OFF Stitches (↑) Value range Number of backward 01 – 50 stitches Stitches (↓) Value range Number of forward 01 –...
  • Page 72 Programming Menu items Setting option 1 Setting option 2 ON/OFF Catch Backtack, Bartack before Stitches (↑) Value range the bartack 01 - 50  p. 71 Stitches (↓) Value range 01 - 50 ON/OFF First Repet., Number of stitches Stitches (↑/↓) Value range different for 1 section...
  • Page 73 Programming Setting: Single stitches per pedal (Pedal Stop) If this function is activated, each stitch in the bartack can be sewn individually by pressing the pedal. This function can only be used meaningfully if the speed is set very low for the bartack. Setting: Default needle thread tension (Thr.Tens.Def.) If this function is active, the same needle thread tension is used for the bartack as the one set in Manual mode.

  • Page 74: Setting The End Bartack Parameter (End Tack)

    Programming Setting: Invert direction (Invert Dir.) Normally, a bartack starts either with the sewing direction (forwards – even number of sections) or against the sewing direction (backwards – odd number of sections), depending on the number of sections. Setting this parameter inverts the sewing direction of the bartack. 5.4.7 Setting the End bartack parameter (End Tack) There are various options for setting the end bartack.
  • Page 75 Programming Menu items Setting option 1 Setting option 2 Value range Speed Speed in bartack 0000 – 2000 ON/OFF Pedal Stop, Single stitches per pedal  p. 71 ON/OFF Value range Thr.Tens.Def, Default needle thread 01 - 99 tension  p. 71 ON/OFF Catch Backtack, Bartack after...

  • Page 76: Setting The Sewing Foot Lift Parameter (Foot)

    Programming 5.4.8 Setting the Sewing foot lift parameter (Foot) The sewing foot lift can have various settings. Possible settings and the corresponding value ranges are listed in the table. Menu item Setting option ON = on FL AtStop, Sewing foot lift when OFF = off sewing stops ON = on...

  • Page 77: Setting The Bobbin Monitor Parameter (Bobbin)

    Programming 5.4.9 Setting the Bobbin monitor parameter (Bobbin) The amount of remaining thread on the bobbin can be monitored optically or by software using this setting. Information The bobbin monitor setting is global and NOT limited to an oper- ating mode or a seam program. Settings that are more complex and therefore require further explanation are described in more detail after the table.
  • Page 78 Programming Setting: Monitor (Monitor) Monitor mode can only be used if the additional equipment of the remaining thread monitor is present on the machine. Monitor mode allows for optical monitoring of the bobbin. The possible settings are listed in the table. Duration for which the lens is blown t Clean Value range 0000 –...

  • Page 79: Setting The Information Parameter (Infoscreen)

    Programming 5.4.10 Setting the Information parameter (InfoScreen) Information can be displayed on certain settings during sewing as desired or required. Fig. 39: Display with information shown 4 +000 +00 -013 Possible settings for the Information parameter Symbol Menu item Meaning no display Bobbin stitch counter Bobbin Cnt...

  • Page 80: Setting The Puller Parameter (Puller)

    Programming 5.4.11 Setting the Puller parameter (Puller) The puller supports the transport of the sewing material. The feed of the two rollers is calculated automatically based on the stitch length of the machine. An adjustment may be necessary depend- ing on the application. The rollers of the puller can be adjusted separately.

  • Page 81: Setting The Correction Of Effects Of High Speed (Speed Corr.) Parameter

    Programming 5.4.13 Setting the Correction of effects of high speed (Speed Corr.) parameter Some parameters are affected by high speeds because of the resulting physical effects. To counteract these effects and to achieve consistent results, even at high speeds, adjustment factors can be set depending on the speed.
  • Page 82 Programming Overview of settings modes The correction of the effects of high speeds can be identified in various modes and responded to depending on the setting. This general explanation can be applied to the following specific parameters. Setting mode Description In the linear setting, the size of the parameter linear increases or decreases steadily as the speed...
  • Page 83 Programming Setting: Stitch length (Stitchlen.) The stitch length changes slightly depending on the speed. For this reason, the stitch length can be adjusted at different speeds by the software. Maximum stitch length variation linear Stitch length Value range -50 – 50 [%] reached at the upper speed limit.
  • Page 84 Programming Setting: Needle thread tension (Thr.Tens.) Depending on the speed, the needle thread tension can be adjusted at different speeds by the software. Maximum needle thread linear Thr.Tens. Value range tension reached at the upper 00 – 99 speed limit. Speed at which the increase Min.

  • Page 85: Setting The Material Thickness Detection (Fabricthickness) Parameter

    Programming 5.4.14 Setting the Material thickness detection (FabricThickness) parameter To achieve consistently good sewing results for different material thicknesses, some parameters can be adjusted specifically to the material thickness. Settings that are more complex and therefore require further explanation are described in more detail after the table. Menu items Setting option 1 Setting option 2...
  • Page 86 Programming Menu items Setting option 1 Setting option 2 Foot Press., Sewing foot linear Foot Press. pressure  p. 87 ThickMin ThickMax Max. Speed, Speed  p. 87 linear Max. Speed ThickMin ThickMax Overview of settings modes The material thickness can be identified in various modes and responded to depending on the setting.
  • Page 87 Programming Setting: Sewing foot stroke (Stroke) The sewing foot stroke can be adjusted to different material thicknesses by the software. Maximum sewing foot linear Stroke stroke reached at the Value range 00 – 09 [mm] upper material thickness limit. Material thickness at which ThickMin Value range 00.0 –...
  • Page 88 Programming Setting: Stitch length (Stitchlen.) The stitch length changes slightly depending on the material thick- ness. For this reason, the stitch length can be adjusted at different material thicknesses by the software. Maximum stitch length linear stitch length. Value range -50 – 50 [%] variation reached at the upper material thickness limit.
  • Page 89 Programming Setting: Needle thread tension (Thr.Tens.) Depending on the material thickness, the needle thread tension can be adjusted at different material thicknesses by the software. Maximum needle thread linear Thr.Tens. Value range 00 – 99 tension reached at the upper material thickness limit.

  • Page 90: Setting The Light Barrier (Lightbarrier) Parameter

    Programming 5.4.15 Setting the Light barrier (LightBarrier) parameter The light barrier detects the beginning and the end of the material. After a signal was detected, sewing can continue automatically with the specifically set parameters. Menu item Setting option ON = on Light barrier OFF = off ON/OFF...

  • Page 91: Setting The Outputs Parameter (Output)

    Programming Setting: Distance after detection of end of material (Distance) Here, you can set the distance from the detection of the signal to the end of the material. This distance signifies the path from the needle to the light barrier. The path is specified in millimeters and used by the machine to independently calculate the number of stitches.

  • Page 92: Using Automatic Mode

    Programming Using Automatic mode Automatic mode includes all program numbers from 001 to 999. To access Automatic mode: ◄/► to select the Program parameter. ▲/▼ to select the program number 001 or another one (if available).  The software switches to Automatic mode, the program name is shown briefly, and then the following display appears: Fig.

  • Page 93: Sewing In Automatic Mode

    Programming Symbol Description Stitch length correction factor Value range: -50 – 50 [%] Alters the stitch length in all seam sections Allows for finer with ▲/▼. adjustment than by setting Default needle thread tension adjustment the parameters factor directly. Value range: -50 – 50 [%] Alters the needle thread tension in all seam sections with ▲/▼.
  • Page 94 Programming Fig. 42: Seam section in progress Completed seam sections are shown fully in bold. Fig. 43: Completed seam section Additional information is shown next to the program bar, which can be identified at a glance thanks to the small symbols on the display: Symbol Meaning...

  • Page 95: Canceling A Program In Automatic Mode

    Programming Possible actions in the course of the seam The following table lists the functions that can be performed in the course of the seam. Button/Pedal Function ◄/► Seam section forwards/backwards or go to start of seam section. Pedal halfway Lift sewing foot.

  • Page 96: Using Programming/Edit Mode

    Programming Using Programming/Edit mode 5.6.1 Creating a new program To create a new program: Press the button.  The softkey menu appears. Press the button.  The control displays the next free program number. Fig. 44: Creating a new program Press the OK button to load the program number.

  • Page 97: Creating A Program Using Keyboard Input

    Programming 5.6.2 Creating a program using keyboard input Creating a program using keyboard input is done completely without sewing. All parameters for the seam sections and the program are entered manually. To create a program using keyboard input: Create a new program,  p. 94. ►...
  • Page 98 Programming Symbol Meaning Needle thread tension value (%) of current seam section Value range: 00 - 99 • Use ◄/► to select the Needle thread tension parameter • Use ▲/▼ to change the needle thread tension. Information If the values for the needle thread tension of the right and the left needle thread are not identical and changed jointly, the difference remains the same.

  • Page 99: Creating A Program Using Teach-In

    Programming 5.6.3 Creating a program using Teach-In Creating a program using Teach-In is done by sewing the seam sections and manually entering the parameters for the seam sections and the program. To create a program using Teach-In: Create a new program,  p. 94. Press the Teach-In button.

  • Page 100: Adjusting Parameters For The Current Seam Section

    Programming Symbol Meaning Sewing foot pressure Value range: 01 - 20 • Use ◄/► to select the Sewing foot pressure parameter. • Use ▲/▼ to change the sewing foot pressure Stroke Value range: 00.0 – 09.0 [mm] (0.5 mm increments) •...
  • Page 101 Programming Press the OK button to activate or deactivate the parameter ▲/▼ or use to edit the value and confirm the change by press- ing the OK button. Parameters for the current seam section: Symbol Description Stitch counter Length of the seam section 0 = Manually step through >...

  • Page 102: Adjusting Parameters For The Selected Program

    Programming Symbol Description FL height Lifting height of the sewing foot when sewing stops on the seam section. Backwards Backward stitches; when the parameter is activated, the section is sewn backwards. Puller Supports the transport of the sewing material, setting identical to Manual mode, ...
  • Page 103 Programming To adjust the parameters for the selected program: ◄/► to select the field Press the OK button.  The submenu opens. ▲/▼ to select the desired parameter. Press the OK button to activate or deactivate the parameter ▲/▼ or use to edit the value and confirm the change by press- ing the OK button.
  • Page 104 Programming Parameters for selected program: Symbol Description Prog. Name A program name can be entered using the numeric buttons: • Use ◄/► to navigate forwards and backwards • Use the F button to delete a letter • Use the OK button to confirm the entry •...

  • Page 105: Editing Programs

    Programming Symbol Description PointPos.° Setting identical to Manual mode,  p. 68. Speed Corr Setting identical to Manual mode,  p. 79. Mat.Thickness If present, setting identical to Manual mode,  p. 83. ◄ Exit the submenu using the ESC or button.

  • Page 106: Copying The Program

    Programming ▲/▼ Select the seam section to be changed using with  The selected seam section is shown in bold in the program bar. Adjust the basic parameters. Adjust the parameters for the selected seam section,  p. 98. Adjust the parameters for the entire program,  p. 100. to add a new seam section.
  • Page 107 Programming Fig. 50: Copying the program  The control displays the next free program number. Press the OK button to load the program number. ▲/▼ Select another program number using or input a program number using the numeric buttons 0 – 9. Press the OK button to confirm the program number.

  • Page 108: Deleting The Program

    Programming 5.6.8 Deleting the program Only the selected program can be deleted. To delete a program: Select the desired program. Press the P button.  The P above the program number will flash. Press the Softkey menu button.  The softkey menu appears. Fig.

  • Page 109: Maintenance

    Maintenance Maintenance WARNING Risk of injury from sharp parts! Punctures and cutting possible. Prior to any maintenance work, switch off the machine or set the machine to threading mode. WARNING Risk of injury from moving parts! Crushing possible. Prior to any maintenance work, switch off the machine or set the machine to threading mode.

  • Page 110: Cleaning

    Maintenance Work to be carried out Operating hours Servicing the pneumatic system  Setting the operating pressure  Draining the water condensation  Cleaning the filter element Cleaning WARNING Risk of injury from flying particles! Flying particles can enter the eyes, causing injury. Wear safety goggles.
  • Page 111 Maintenance NOTICE Property damage from solvent-based cleaners! Solvent-based cleaners will damage paintwork. Use only solvent-free substances for cleaning. Fig. 53: Areas requiring special cleaning ① ② ④ ② ③ (1) - Area around the needles (3) - Area under the throat plate (2) - Hook (4) - Cutter on the winder Areas particularly susceptible to soiling:...

  • Page 112: Lubricating

    Maintenance Lubricating CAUTION Risk of injury from contact with oil! Oil can cause a rash if it comes into contact with skin. Avoid skin contact with oil. If oil has come into contact with your skin, wash the affected areas thoroughly. NOTICE Property damage from incorrect oil! Incorrect oil types can result in damage to the machine.

  • Page 113: Lubricating The Machine Head

    Maintenance 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 6.2.1 Lubricating the machine head Proper setting The oil level is between the minimum level marking and the maximum level marking.

  • Page 114: Lubricating The Hook

    Maintenance 6.2.2 Lubricating the hook The approved oil quantity for hook lubrication is a factory specification. Proper setting Hold a piece of blotting paper next to the hook. Allow the machine to run without thread and sewing material for 10 seconds with the sewing feet lifted and at a high speed. ...

  • Page 115: Servicing The Pneumatic System

    Maintenance Servicing the pneumatic system 6.3.1 Setting the operating pressure NOTICE Property damage from incorrect setting! Incorrect operating pressure can result in damage to the machine. Ensure that the machine is only used when the operating pressure is set correctly. Proper setting Refer to the Technical data (...

  • Page 116: Draining The Water Condensation

    Maintenance To set the operating pressure: Pull the pressure controller (1) up. Turn the pressure controller until the pressure gage (2) indi- cates the proper setting: • Increase pressure = turn clockwise • Reduce pressure = turn counterclockwise Push the pressure controller (1) down. 6.3.2 Draining the water condensation NOTICE...
  • Page 117 Maintenance Fig. 57: Draining the water condensation ① ③ ② (1) - Filter element (3) - Drain screw (2) - Water separator 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.

  • Page 118: Cleaning The Filter Element

    Maintenance 6.3.3 Cleaning the filter element NOTICE Damage to the paintwork from solvent-based cleaners! Solvent-based cleaners damage the filter. Use only solvent-free substances for washing out the filter tray. Fig. 58: Cleaning the filter element ① ③ ② (1) - Filter element (3) - Drain screw (2) - Water separator To clean the filter element:...

  • Page 119: Parts List

    Maintenance Tighten the water separator (2). 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 PREMIUM - 02.0 - 01/2018...
  • Page 120 Maintenance Operating Instructions 868-M PREMIUM - 02.0 - 01/2018...

  • Page 121: Setup

    Setup Setup WARNING Risk of injury from cutting parts! Cutting injuries may be sustained while unpacking and setting up the machine. Only qualified specialists may set up the machine. Wear safety gloves WARNING Risk of injury from moving parts! Crushing injuries may be sustained while unpacking and setting up the machine.

  • Page 122: Assembling The Stand

    Setup Assembling the stand Fig. 59: Assembling the stand ⑧ ① ① ④ ② ⑦ ⑤ ③ ⑥ ④ ⑤ (1) - Inner bar (5) - Foot strut (2) - Oil can holder (6) - Cross strut (3) - Adjusting screw (7) - Cross bar (4) - Stand bar (8) - Head section - inner bar...

  • Page 123: Assembling The Pedal And Setpoint Device

    Setup Assembling the pedal and setpoint device Fig. 60: Assembling the pedal and setpoint device ⑥ ⑤ ① ② ③ ④ (1) - Pedal rod (4) - Pedal (2) - Screw (5) - Setpoint device (3) - Cross strut (6) - Bracket To assemble pedal and setpoint device: Fit the pedal (4) on the cross strut (3) and align it in such a way that the middle of the pedal is under the needle.

  • Page 124: Tabletop

    Setup Proper setting 10° inclination with pedal (4) released Tighten the screw (2). Tabletop Ensure that the tabletop has sufficient load-bearing capacity and strength. If you want to make your own tabletop, use the dimen- sions given in the diagram Appendix ( p. 159) as a template. 7.5.1 Completing the tabletop The tabletop is optional.

  • Page 125: Assembling The Tabletop To The Stand

    Setup To complete the tabletop: Screw the drawer (3) with the left-hand bracket to the under- side of the tabletop. Screw the oil pan (3) in place under the slot for the machine. Screw the cable duct (1) to the underside of the tabletop. Insert the reel stand (4) into the hole.

  • Page 126: Setting The Working Height

    Setup Setting the working height WARNING Risk of injury from moving parts! The tabletop can sink under its own weight when the screws on the stand bars are loosened. Crushing possible. Ensure that your hands are not jammed when loosening the screws. CAUTION Risk of musculoskeletal damage from incorrect setting!

  • Page 127: Assembling The Control

    Setup To set the working height: Loosen the screws (1) on the stand bars. Set the tabletop to the desired height. Important Pull out or push in the tabletop evenly at both sides to prevent it from jamming. Tighten the screws (1) on the stand bars. Assembling the control Fig.

  • Page 128: Placing The Machine Head

    Setup Placing the machine head WARNING Risk of injury from moving parts! The machine head is very heavy. Crushing possible. Ensure that your hands are not jammed when inserting the machine head. NOTICE Property damage may occur! Cable may sustain damage and impair the operation of the machine.

  • Page 129: Assembling The Control Panel

    Setup Assembling the control panel Fig. 66: Assembling the control panel ① ② ② (1) - Control panel (3) - Bracket (2) - Plug To assemble the control panel: Tighten the control panel (1) on the bracket (3). Insert the plug (2) of the connecting cable into the socket of the control panel (1).

  • Page 130: Assembling The Knee Button

    Setup 7.10 Assembling the knee button Fig. 67: Assembling the knee button ① ③ ② (1) - Knee button (3) - Plug (2) - Connecting cable To assemble the knee button: Screw the knee button (1) in front of the oil pan firmly in place under the tabletop.

  • Page 131: Electrical Connection

    Setup 7.11 Electrical connection DANGER Risk of death from live components! Unprotected contact with electricity can result in serious injuries or death. Only qualified specialists may perform work on electrical equipment. Important The voltage on the type plate of the sewing motor must correspond to the mains voltage.

  • Page 132: Connecting The Sewing Lamp Transformer

    Setup 7.11.1 Connecting the sewing lamp transformer DANGER Risk of death from electric shock! When the sewing machine is switched off at the main switch, the supply voltage for the sewing lamp remains active. Disconnect the power plug before assembling the sewing lamp with sewing lamp transformer.
  • Page 133 Setup Fig. 69: Connecting the sewing lamp transformer (2) ③ ② ⑤ ④ ③ (2) - Adapter cover screws (4) - 24V/X5 connection (3) - Screw holder (5) - X3 connection Connecting the sewing lamp transformer Loosen the screw holder (3) for the control until the control can be removed.

  • Page 134: Establishing Equipotential Bonding

    Setup 7.11.2 Establishing equipotential bonding DANGER Risk of death from live components! Unprotected contact with electricity can result in serious injuries or death. Disconnect the power plug before establishing equipotential bonding. Ensure the power plug cannot be unintentionally reinserted. The grounding wire conducts away any static charging of the machine head.

  • Page 135: Connecting The Control

    Setup 7.11.3 Connecting the control DANGER Risk of death from live components! Unprotected contact with electricity can result in serious injuries or death. Disconnect the power plug before connecting the control. Ensure the power plug cannot be unintentionally reinserted. To connect the control: Connect the control as specified in the wiring diagram (...

  • Page 136: Pneumatic Connection (Optional)

    Setup 7.12 Pneumatic connection (optional) NOTICE Property damage from oily compressed air! Oil particles in the compressed air can cause malfunctions of the machine and soil the sewing material. Ensure that no oil particles enter the compressed air supply. NOTICE Property damage from incorrect setting! Incorrect system pressure can result in damage to the machine.

  • Page 137: Assembling The Compressed Air Maintenance Unit

    Setup 7.12.1 Assembling the compressed air maintenance unit Fig. 71: Assembling the compressed air maintenance unit ④ ① ③ ② (1) - Cross bar (3) - Maintenance unit (2) - System connection hose (4) - Machine hose To assemble the compressed air maintenance unit: Assemble the compressed air maintenance unit (3) to the upper cross bar (1) of the stand using the bracket, screws and clip.

  • Page 138: Setting The Operating Pressure

    Setup 7.12.2 Setting the operating pressure NOTICE Property damage from incorrect setting! Incorrect operating pressure can result in damage to the machine. Ensure that the machine is only used when the operating pressure is set correctly. Proper setting Refer to the Technical data ( p. 157) chapter for the permissi- ble operating pressure.

  • Page 139: Checking The Lubrication

    Setup Turn the pressure controller until the pressure gage (2) indi- cates the proper setting: • Increase pressure = turn clockwise • Reduce pressure = turn counterclockwise Push the pressure controller (1) down. 7.13 Checking the lubrication All wicks and felt bits of the machine head are soaked in oil at the factory.

  • Page 140: Performing A Test Run

    Setup 7.14 Performing a test run WARNING Risk of injury from moving, cutting and sharp parts! Crushing, cutting and punctures are possible. If possible, only change settings when the machine is switched off. When setup is complete, perform a test run to check the function- ality of the machine.

  • Page 141: Decommissioning

    Decommissioning Decommissioning WARNING Risk of injury from a lack of care! Serious injuries may occur. ONLY clean the machine when it is switched off. Allow ONLY trained personnel to disconnect the machine. CAUTION Risk of injury from contact with oil! Oil can cause a rash if it comes into contact with skin.
  • Page 142 Decommissioning Operating Instructions 868-M PREMIUM - 02.0 - 01/2018...

  • Page 143: Disposal

    Disposal Disposal CAUTION Risk of environmental damage from improper disposal! Improper disposal of the machine can result in serious environmental damage. ALWAYS comply with the national regulations regarding disposal. The machine must not be disposed of in the normal household waste.
  • Page 144 Disposal Operating Instructions 868-M PREMIUM - 02.0 - 01/2018...

  • Page 145: Troubleshooting

    Troubleshooting 10 Troubleshooting 10.1 Customer Service Contact for repairs and issues with the machine: Dürkopp Adler AG Potsdamer Str. 190 33719 Bielefeld, Germany Tel. +49 (0) 180 5 383 756 Fax +49 (0) 521 925 2594 Email: service@duerkopp-adler.com Internet: www.duerkopp-adler.com Operating Instructions 868-M PREMIUM - 02.0 - 01/2018...

  • Page 146: Messages Of The Software

    Troubleshooting 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. 10.2.1 Information messages Code Possible cause Remedial action 3104 Pedal is not in position 0 •...
  • Page 147 Troubleshooting Code Possible cause Remedial action 4442 OP3000: DAC unknown • Check connection to OP3000 message • Replace OP3000 • Replace the control 4443 OP3000: DAC invalid • Check connection to OP3000 checksum • Replace OP3000 • Replace the control 4446 OP3000: DAC •...
  • Page 148 Troubleshooting Code Possible cause Remedial action 5004 Checksum error • Perform reset 6360 No valid data on external • Perform software update EEprom (internal data structures are not compatible with the external data storage device) 6361 No external EEprom • Connect machine ID connected 6362 No valid data on internal...
  • Page 149 Troubleshooting Code Possible cause Remedial action 6366 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) 7270 External CAN •...

  • Page 150: Error Messages

    Troubleshooting 10.2.2 Error messages Code Possible cause Remedial action 1000 Sewing motor encoder • Connect encoder cable to the plug (Sub-D, 9-pin) not control, use correct connection connected 1001 Sewing motor error: • Check connection and plug in, if Sewing motor plug necessary (AMP) not connected •...
  • Page 151 Troubleshooting Code Possible cause Remedial action 1008 Encoder error • Replace the encoder 1010 External synchronizer • Connect cable of external plug (Sub-D, 9-pin) not synchronizer to control, use correct connected connection (Sync) • Only required for machines with transmission! 1011 Encoder Z pulse •...
  • Page 152 Troubleshooting Code Possible cause Remedial action 1203 Position not reached • Check and, if necessary, change controller settings • Mechanical changes to the machine (e.g. thread cutting setting, belt tension) 1302 Sewing motor voltage • Check service stop switch error •...
  • Page 153 Troubleshooting Code Possible cause Remedial action 2222 DA stepper card Y • Check stepper motor 1 for stiff flywheel position not movement found 2230 DA stepper card Y not • Perform software update responding • Replace the control 2231 DA stepper card Y Init •...
  • Page 154 Troubleshooting Code Possible cause Remedial action 2371 DA stepper card Z • Perform software update watchdog (sewing foot • Check class lift) 2401 DA stepper card U • Check reference sensor reference run timeout (edge stop) 2430 DA stepper card U not •...
  • Page 155 Troubleshooting Code Possible cause Remedial action 3100 AC-RDY timeout, • Check the mains voltage intermediate circuit • If the mains voltage is OK, replace voltage did not reach the control the defined threshold in the specified time 3101 High voltage fault, •...
  • Page 156 Troubleshooting Code Possible cause Remedial action 4450 OP3000: DAC receive • Check connection to OP3000 buffer overflow • Replace OP3000 • Replace the control 9330 Material thickness • Check connection cables sensor not connected • Perform software update • Replace material thickness sensor 9922 Service stop •...

  • Page 157: Errors In Sewing Process

    Troubleshooting 10.3 Errors in sewing process Error Possible causes Remedial action Unthreading Needle thread pretension Check needle thread at seam is too firm pretension ( p. 42). beginning Thread Needle thread and hook Check threading path breaking thread have not been (...
  • Page 158 Troubleshooting Error Possible causes Remedial action Missing Needle thread and hook Check threading path ( p. 26,  p. 40). stitches thread have not been threaded correctly Needle is blunt or bent Replace the needle ( p. 22). Needle is not inserted Insert the needle correctly correctly into the needle into the needle bar...

  • Page 159: Technical Data

    Technical data 11 Technical data Data and characteristic values Technical data Unit Type of stitches Double lockstitch 301 Hook type Vertical, large Number of needles Needle system 134-35 Needle strength [Nm] Nm 90 to Nm 180 Thread strength [Nm] Nm 80/3 to Nm 10/3 Stitch length [mm] Speed maximum...
  • Page 160 Technical data Characteristics • sewing motor (DA direct drive) integrated into the machine head with max. speed of 2,800 rpm • DAC comfort control with OP3000 control panel (including control panel holder) • Actuators without compressed air • Equipped with large (L) vertical hook •...

  • Page 161: Appendix

    Appendix 12 Appendix Fig. 74: Tabletop drawing (1) Operating Instructions 868-M PREMIUM - 02.0 - 01/2018...
  • Page 162 Appendix Fig. 75: Tabletop drawing (2) Operating Instructions 868-M PREMIUM - 02.0 - 01/2018...
  • Page 164 DÜRKOPP ADLER AG 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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