Dürkopp Adler D869 e-con Service Instructions Manual
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Dürkopp Adler D869 e-con Service Instructions Manual

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Summary of Contents for Dürkopp Adler D869 e-con

  • Page 1 D869 e-con Service Instructions...
  • Page 2 IMPORTANT READ CAREFULLY BEFORE USE KEEP FOR FUTURE REFERENCE All rights reserved. Property of Dürkopp Adler GmbH and protected by copyright. Any reuse of these contents, including extracts, is prohibited without the prior written approval of Dürkopp Adler GmbH. Copyright © Dürkopp Adler GmbH 2023...

  • Page 3: Table Of Contents

    Adjusting the hook side clearance ..........53 Adjusting the looping stroke position ........56 Adjusting the needle guard ............57 Adjusting the needle bar height ..........58 Adjusting the bobbin case lifter ..........60 Service Instructions D869 e-con - 00.0 - 09/2023...
  • Page 4 17.4.6 Setting the Needle thread tension parameters ..... 123 17.4.7 Setting the Sewing foot stroke parameters....125 17.4.8 Setting the Stitch length parameters ......127 17.4.9 Setting the RFW/SSD parameters ........... 129 Service Instructions D869 e-con - 00.0 - 09/2023...
  • Page 5 17.8.7 Network................. 185 17.8.8 Logging................. 185 17.8.9 Logger modules ..............186 17.9 Information ................ 188 17.10 Performing a software update .......... 190 Maintenance ................191 18.1 Cleaning.................. 192 18.2 Lubricating ................193 Service Instructions D869 e-con - 00.0 - 09/2023...
  • Page 6 Requirements for fault-free operation ........227 Appendix ................229 23.1 Barcode examples ..............229 23.2 Converting videos for playback on the control panel ....230 23.3 Basic settings of the machine ..........233 23.4 Wiring diagram................ 234 Service Instructions D869 e-con - 00.0 - 09/2023...

  • Page 7: About These Instructions

    Proper setting Specifies proper setting. Disturbances Specifies the disturbances that can occur from an incorrect setting. Cover Specifies which covers must be disassembled in order to access the components to be set. Service Instructions D869 e-con - 00.0 - 09/2023...
  • Page 8 Safety ( p. 9). If no other clear location information is used in a figure, indications of right Location information or left are always from the user's point of view. Service Instructions D869 e-con - 00.0 - 09/2023...

  • Page 9: Other Documents

    European and national regulations. The proper use of the built-in components is described in the corresponding manufacturer's instructions. Service Instructions D869 e-con - 00.0 - 09/2023...

  • Page 10: Liability

    Leave machines, equipment and packaging material in the condition in which they were found when the damage was discovered. This will ensure any claims against the transport company. Report all other complaints to Dürkopp Adler immediately after receiving the product. Service Instructions D869 e-con - 00.0 - 09/2023...

  • Page 11: Safety

    • Setting up the machine/putting the machine into operation • Performing maintenance work and repairs • Performing work on electrical equipment Only authorized persons may work on the machine and must first have understood these instructions. Service Instructions D869 e-con - 00.0 - 09/2023...

  • Page 12: Signal Words And Symbols Used In Warnings

    If ignored, environmental damage can result NOTICE (without hazard symbol) If ignored, property damage can result The following symbols indicate the type of danger to personnel: Symbols Icon Type of danger General Electric shock Service Instructions D869 e-con - 00.0 - 09/2023...
  • Page 13 Consequences of non-compliance. Measures for avoiding the danger.  This is what a warning looks like for a hazard that could result in moderate or minor injury if the warning is ignored. Service Instructions D869 e-con - 00.0 - 09/2023...
  • Page 14 Type and source of danger! Consequences of non-compliance. Measures for avoiding the danger.  This is what a warning looks like for a hazard that could result in property damage if ignored. Service Instructions D869 e-con - 00.0 - 09/2023...

  • Page 15: Working Basis

    3. Cut off any overlapping cable ties. NOTICE Property damage may occur! Excess cables can impair the functioning of moving machine parts. This impairs the sewing function and can result in damage. Lay excess cables as described above. Service Instructions D869 e-con - 00.0 - 09/2023...

  • Page 16: Calling Up The Service Routine

    Equal sewing foot stroke (setting an even sewing foot stroke) Sewing foot stroke Feed Move (setting the feeding foot movement)  The display shows all the values set in the selected service routine. Service Instructions D869 e-con - 00.0 - 09/2023...
  • Page 17  The machine moves to the programmed position and is switched off. The button lights up. The display shows the information that the Service Stop is active: Fig. 3: Calling up the service routine (3) Service Instructions D869 e-con - 00.0 - 09/2023...
  • Page 18 Fig. 5: Calling up the service routine (5) 9. Press the button.  You are now in the service menu again. 10. Press the button.  The machine moves back to its initial position and is ready to sew. Service Instructions D869 e-con - 00.0 - 09/2023...

  • Page 19: Disassembling And Assembling The Covers

    The text for each type of adjustment work then specifies only the cover that needs to be disassembled at that particular time. Information Always apply 1 Nm of tightening torque when tightening the screws that are used to attach the covers. Service Instructions D869 e-con - 00.0 - 09/2023...

  • Page 20: Tilting The Machine Head

    To erect the machine head: 1. Erect the machine head (1). For safety reasons, the machine head (1) is stopped by the bolt (2). 2. Lift the lever (3) and erect the machine head (1) completely. Service Instructions D869 e-con - 00.0 - 09/2023...

  • Page 21: Disassembling And Assembling The Arm Cover

    To disassemble the arm cover: 1. Loosen the screws (2). 2. Disassemble the arm cover (1). Assembling the arm cover To assemble the arm cover: 1. Assemble the arm cover (1). 2. Tighten the screws (2). Service Instructions D869 e-con - 00.0 - 09/2023...

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

    Assembling the front cover To assemble the front cover: 1. Switching off the machine 2. Place the front cover (1). Make sure not to damage the thread lever. 3. Tighten the screws (2). Service Instructions D869 e-con - 00.0 - 09/2023...

  • Page 23: Disassembling And Assembling The Head Cover

    Attention: 2 screws at the front on the head cover, 2 screws on the rear of the machine. 2. Disassemble the head cover (1). Assembling the head cover To assemble the head cover: 1. Assemble the head cover (1). Service Instructions D869 e-con - 00.0 - 09/2023...

  • Page 24: Disassembling And Assembling The Motor Cover

    3. Disassemble the motor cover (2). Assembling the motor cover To assemble the motor cover: 1. Set the lever (3) vertical. 2. Assemble the motor cover (2). 3. Tighten the screws (1). Service Instructions D869 e-con - 00.0 - 09/2023...

  • Page 25: Disassembling And Assembling The Toothed Belt Cover

    1. Loosen screws (4) on the handwheel (4). 2. Remove the handwheel (3). 3. Loosen the screws (1). 4. Remove the toothed belt cover (2); start by disassembling the cover from below. Service Instructions D869 e-con - 00.0 - 09/2023...
  • Page 26 (6) - Centering pin 3. Place the handwheel (3), making sure that the centering pin (6) is posi- tioned correctly (otherwise, referencing by the hall sensor will not work properly). 4. Tighten the screws (4). Service Instructions D869 e-con - 00.0 - 09/2023...

  • Page 27: Disassembling And Assembling The Thread Tension Plate

    Make sure not to lose the bobbin case retainer (4) as it will otherwise no longer be possible to connect the push button. 4. Loosen screws (1) and (2). 5. Remove the thread tension plate (3). Service Instructions D869 e-con - 00.0 - 09/2023...
  • Page 28 2. Assemble the thread tension plate (3). 3. Tighten screws (1) and (2). 4. Slip plugs onto the PCB: • Thread clamp: Connection X10 (optional) • Thread tension: Connection X11 • Push button: Connection X12 Service Instructions D869 e-con - 00.0 - 09/2023...

  • Page 29: Disassembling And Assembling The Throat Plate Slide

    1. Push down the thread (2) and pull off the throat plate slide (1). Closing the throat plate slide To close the throat plate slide: 1. Place the throat plate slide (1) on the spring (2) and slide it towards the needle. Service Instructions D869 e-con - 00.0 - 09/2023...

  • Page 30: Disassembling And Assembling The Throat Plate

    1. Place the throat plate (1). Make sure the nose (3) is positioned in the slot. Fig. 18: Disassembling the throat plate (2) ① ③ (1) - Throat plate - Nose 2. Tighten the screws (2). Service Instructions D869 e-con - 00.0 - 09/2023...
  • Page 31 1. Place the throat plate (2) in accordance with the sewing direction. Make sure that the nose (5) is positioned in the slot on both sides. Fig. 20: Disassembling and assembling the throat plate (4) ① ⑤ - Throat plate (5) - Nose Service Instructions D869 e-con - 00.0 - 09/2023...

  • Page 32: Disassembling And Assembling The Feed Dog

     The software is used to define the necessary presettings on the machine. 3. Press the Service Stop button. Important The maximum permissible stitch length can be set in the service routine. 4. Disassemble walking foot (1), presser foot (2) and needle. Service Instructions D869 e-con - 00.0 - 09/2023...
  • Page 33 The feed dog does not touch the throat plate with the maximum permissi- ble stitch length. Disassembling the feed dog To disassemble the feed dog on 2-needle machines: 1. Execute the service routine Feed dog > Assemble ( p. 14). Service Instructions D869 e-con - 00.0 - 09/2023...

  • Page 34: Flats On Shafts

    Fig. 23: Flats on shafts ① ② (1) - Flat (2) - Shaft Some shafts have flat surfaces at the points where the components are screwed on. This stabilizes the connection and makes adjusting easier. Service Instructions D869 e-con - 00.0 - 09/2023...
  • Page 35 Working basis Important Always ensure that the screws are completely flush with the surface. The rule is to always place the 1 screw in rotational direction onto the flat. Service Instructions D869 e-con - 00.0 - 09/2023...

  • Page 36: Locking The Machine In Place

    2. Turn the handwheel carefully until the locking peg (1) slides into the slot on the arm shaft crank. Removing the lock To remove the lock: 1. Pull the locking peg (1) out of the slot in the machine arm. Service Instructions D869 e-con - 00.0 - 09/2023...

  • Page 37: Adjusting The Handwheel Into Position

    (1) is next to the marking (2). Information When the Service Stop is activated, the handwheel is easier to turn and the degree number can be read on the control panel. Service Instructions D869 e-con - 00.0 - 09/2023...
  • Page 38 Working basis Service Instructions D869 e-con - 00.0 - 09/2023...

  • Page 39: Positioning The Arm Shaft Crank On The Arm Shaft

    6. Push the arm shaft with the arm shaft crank (1) to the right as far as it will go and flush with the machine casting (3). 7. Tighten the threaded pins (2). Service Instructions D869 e-con - 00.0 - 09/2023...

  • Page 40: Performing The Basic Settings Of The Eccentrics

    Feed dog movement Feed dog lift The looping stroke (approx. 202°) ( p. 34) securing position allows you to define the basic settings for sewing foot stroke, feed dog lift and feed dog movement. Service Instructions D869 e-con - 00.0 - 09/2023...
  • Page 41 6. Turn the stroke eccentric (2) such that the upper edge of the feed dog is at the same height as the upper edge of the throat plate during the upward movement. 7. Tighten the threaded pins (3). 8. Finish the service routine. Service Instructions D869 e-con - 00.0 - 09/2023...
  • Page 42 3. Use the Manual bartack button (4) to check if the feed dog is at a standstill. 4. Adjust if necessary ( p. 41). 5. Tilt the machine head ( p. 18). Service Instructions D869 e-con - 00.0 - 09/2023...
  • Page 43 4. Loosen the screw (7). 5. Turn the eccentric such that slot (5) lines up with slot (6). 6. Tighten the screws (7). 7. Remove the lock. 8. Tighten the screw (8). Service Instructions D869 e-con - 00.0 - 09/2023...
  • Page 44 7. Loosen the screws (11). 8. Turn the eccentric such that slot (12) lines up with slot (13). 9. Tighten the screw (11). 10. Remove the lock. 11. Tighten the screw (10). Service Instructions D869 e-con - 00.0 - 09/2023...

  • Page 45: Adjusting The Compensating Weight

    2. Adjust the compensating weight (2) such that screw (1) and screw (4) are at the same height. Make sure there is a gap between the compensating weight (2) and the transmission lever (3). Tighten the screw (1). Service Instructions D869 e-con - 00.0 - 09/2023...

  • Page 46: Adjusting The Mechanical Stitch Adjustment

    0 = no feed) is determined by the Calibration zero stitch ( p. 169). Cover • Remove the toothed belt cover ( p. 23) • Motor cover ( p. 22) • Remove the front cover ( p. 20) Service Instructions D869 e-con - 00.0 - 09/2023...
  • Page 47 3. Pull the cables out of the cable ducts (4). While doing so, make sure not to damage the cables. 4. Insert the locking peg (∅ 5 mm) (2) into the hole (3) on the motor bracket. Service Instructions D869 e-con - 00.0 - 09/2023...

  • Page 48: Adjusting The Forward And Backward Stitch

    The forward and backward stitch are controlled by a stepper motor and adjusted via software. The calibration is performed only in the software and does not require that you mechanically set an eccentric ( p. 169). Service Instructions D869 e-con - 00.0 - 09/2023...

  • Page 49: Adjusting Feed Dog And Needle Bar Linkage

    Information For minimal deviations, it suffices to move the feed dog on the carrier ( p. 48). Service Instructions D869 e-con - 00.0 - 09/2023...
  • Page 50 Place the removed throat plate next to it as an aid for orientation so that the feed dog can be screwed on straight. 8. Tighten screws (1) and (5). 9. Finish the service routine. Service Instructions D869 e-con - 00.0 - 09/2023...

  • Page 51: Aligning The Needle Bar Linkage Sideways

    4. Disassemble the tensioning plate ( p. 25). 5. Position the plates (4) of the stitch regulator flush. 6. Loosen the threaded pins (1) on the set collars (2). 7. Loosen the screw (3). Service Instructions D869 e-con - 00.0 - 09/2023...
  • Page 52 Make sure that the thread lever (9) does not collide with other parts when moving. 14. Tighten the threaded pins (8). Order Then, check the following settings: • Distance between hook and needle ( p. 53) • Looping stroke position ( p. 56) Service Instructions D869 e-con - 00.0 - 09/2023...

  • Page 53: Aligning The Needle Bar Linkage In The Sewing Direction

    6. Move the needle bar linkage until there is a distance of 10 mm between presser bar and walking foot bar. 7. Tighten the screw (1). 8. Finish the service routine. 9. Assemble the front cover. Service Instructions D869 e-con - 00.0 - 09/2023...

  • Page 54: Adjusting The Feed Dog Height At Top Dead Center

    4. Loosen the screw (2). 5. Move the feed dog (3) until it protrudes 0.6 - 0.7 mm from the throat plate. 6. Tighten the screw (2). 7. Finish the service routine. Service Instructions D869 e-con - 00.0 - 09/2023...

  • Page 55: Position Of The Hook And Needle

    2. Tilt the machine head ( p. 18). 3. Remove the free arm cover. 4. Open the throat plate slide. 5. Disassemble the throat plate. 6. Disassemble the feed dog. Service Instructions D869 e-con - 00.0 - 09/2023...
  • Page 56 (3). 16. Remove the lock. 17. Tighten the 1 threaded pin (3). 18. Finish the service routine. Order Then, check the following settings: 19. Position of the needle guard ( p. 57) Service Instructions D869 e-con - 00.0 - 09/2023...
  • Page 57 27. Check the looping stroke position ( p. 56). 28. Tighten the threaded pins (1). 29. Remove the lock. 30. Finish the service routine. Order Then, check the following settings: 31. Position of the needle guard ( p. 57) Service Instructions D869 e-con - 00.0 - 09/2023...

  • Page 58: Adjusting The Looping Stroke Position

    To adjust the looping stroke position: 1. Remove the lock. 2. Execute the service routine Needle-Hook > Timing ( p. 14).  The software is used to define the necessary presettings on the machine. Service Instructions D869 e-con - 00.0 - 09/2023...

  • Page 59: Adjusting The Needle Guard

    To adjust the needle guard: 1. Execute the service routine Needle-Hook > Timing ( p. 14).  The software is used to define the necessary presettings on the machine. Service Instructions D869 e-con - 00.0 - 09/2023...

  • Page 60: Adjusting The Needle Bar Height

    Instructions) Proper setting Machine is locked in place at the looping stroke position (202°) ( p. 34). The hook tip is level with the lower third of the groove on the needle. Service Instructions D869 e-con - 00.0 - 09/2023...
  • Page 61 When doing so, take care not to twist the needle to the side. The groove (3) must face toward the hook. 7. Tighten the screw (2) for the needle bar (1). 8. Finish the service routine. 9. Remove the lock. Service Instructions D869 e-con - 00.0 - 09/2023...

  • Page 62: Adjusting The Bobbin Case Lifter

    Disturbance Disturbances caused by an incorrect setting of the bobbin case lifter: • Thread breaking • Formation of loops on the bottom side of the seam • Loud machine noise Service Instructions D869 e-con - 00.0 - 09/2023...
  • Page 63 Important Ensure that the gap is not so big that the middle part of the hook swings back and forth, hitting the slot in the throat plate (2). Service Instructions D869 e-con - 00.0 - 09/2023...

  • Page 64: Sewing Feet

    Spring pressure always keeps the gear securely in the zero position on the control cam. Order First, check the following setting: • Basic setting of the eccentrics for sewing foot stroke ( p. 38) Service Instructions D869 e-con - 00.0 - 09/2023...
  • Page 65 6. Loosen all plugs from the PCB (3). 7. CAREFULLY remove the PCB (3) with cover (1). While doing so, press the spacers (2) together individually (using a suitable tool if necessary) and lift the PCB (3) gradually. Service Instructions D869 e-con - 00.0 - 09/2023...
  • Page 66 9. Loosen the threaded pins (5). Check if the threaded pins underneath is seated firmly on the flat. If not, tighten the threaded pin so that there is no play. 10. Tighten the threaded pins (5). Service Instructions D869 e-con - 00.0 - 09/2023...
  • Page 67 13. Use your hand to test if the gear (6) is pushed to the 0 position by the spring. 14. Assemble the PCB (3) with cover (1) again. 15. Attach the plug at the circuit board (3). Service Instructions D869 e-con - 00.0 - 09/2023...

  • Page 68: Adjusting An Even Sewing Foot Stroke

    3. Set the feed dog to the level of the throat plate. 4. Loosen the screw (3). 5. Lower presser foot (1) and walking foot (2) to the level of the throat plate. 6. Re-tighten the screw (3). Service Instructions D869 e-con - 00.0 - 09/2023...

  • Page 69: Adjusting The Sewing Foot Pressure And Sewing Foot Lift

    4. Readjust if necessary. 10.3 Adjusting the sewing foot pressure and sewing foot lift Fig. 55: Adjusting the sewing foot pressure and sewing foot lift (1) ① (1) - Locking peg Service Instructions D869 e-con - 00.0 - 09/2023...
  • Page 70 7. Turn the curve (7) until the roller (8) is seated in the recess of the curve (7). 8. To align the lever (5) sideways: The roller (8) must be flush with the curve (7). 9. Tighten the screw (6). Service Instructions D869 e-con - 00.0 - 09/2023...
  • Page 71 When the pedal is pressed completely back, the sewing feet will be raised after the thread is cut so that the sewing material can be removed. Service Instructions D869 e-con - 00.0 - 09/2023...

  • Page 72: Adjusting The Needle Thread Tension

    • Higher needle thread tension: thick sewing material, high thread strengths Proper setting The loop of the needle thread slides at low tension over the thickest point of the hook, without forming loops or snagging. Service Instructions D869 e-con - 00.0 - 09/2023...
  • Page 73 • Reduce the needle thread tension: Slide the needle thread regulator (3) to the left. • Increase the needle thread tension: Slide the needle thread regulator (3) to the right. 6. Tighten screws (1) and (2). Service Instructions D869 e-con - 00.0 - 09/2023...

  • Page 74: Adjusting The Thread Tensioning Spring

    2. Slide the stop (2) to adjust the spring travel. • Longer spring travel: Slide the stop (2) down. • Shorter spring travel: Slide the stop (2) up. 3. Tighten the screw (3). Service Instructions D869 e-con - 00.0 - 09/2023...
  • Page 75 • Longer spring travel: Slide the screw (6) towards the thread tensioning spring. • Shorter spring travel: Slide the screw (6) away from the thread tensioning spring. 5. Tighten the screw (6). Service Instructions D869 e-con - 00.0 - 09/2023...

  • Page 76: Adjusting The Spring Tension

    To adjust the spring tension: 1. Hook the spring balance (1) into the thread tensioning spring. 2. Pull on the spring balance (1) until the thread tensioning spring starts moving. 3. Loosen the knurled nut (3). Service Instructions D869 e-con - 00.0 - 09/2023...
  • Page 77 • Greater spring tension: Turn screw (4) counterclockwise. • Less spring tension: Turn screw (4) clockwise.  The scale (2) of the spring balance (1) indicates the thread tension reading. 5. Tighten the knurled nut (3). Service Instructions D869 e-con - 00.0 - 09/2023...
  • Page 78 1. Hook the front spring balance (1) into the front thread tensioning spring (3). 2. Pull on the spring balance (1) until the thread tensioning spring starts moving. 3. Loosen the threaded pin (8). Service Instructions D869 e-con - 00.0 - 09/2023...
  • Page 79 • Greater spring tension: Turn screw (6) counterclockwise • Less spring tension: Turn screw (6) clockwise  The scale (2) of the spring balance (1) indicates the thread tension reading. 9. Tighten the knurled nut (7). Service Instructions D869 e-con - 00.0 - 09/2023...

  • Page 80: Bobbin Winder

    2. To fine-tune the setting, put a completely filled bobbin onto the winder. 3. Press the winder lever (2) up to the thread as far as it will go by turning the threaded pin (2). Service Instructions D869 e-con - 00.0 - 09/2023...

  • Page 81: Adjusting The Winder Filling Quantity

    To keep the thread from overflowing on the bobbin, observe the following setting tolerances: • Bobbin Ø 32 mm: Ø 31 ± 0.5 mm • Bobbin Ø 28 mm: Ø 27 ± 0.5 mm Service Instructions D869 e-con - 00.0 - 09/2023...

  • Page 82: Adjusting The Bobbin Thread Guide

    • To wind on the bobbin thread further to the front: Turn the bobbin thread guide (2) to the front • To wind on the bobbin thread further to the rear: Turn the bobbin thread guide (2) to the rear 3. Tighten the screw (1). Service Instructions D869 e-con - 00.0 - 09/2023...

  • Page 83: Thread Trimmer

    3. Move the thread-pulling knife (2) in such a way that the distance between the thread-pulling knife (2) and the middle part of the hook is 0.3 mm. 4. Tighten the screw (3). Service Instructions D869 e-con - 00.0 - 09/2023...

  • Page 84: Adjusting The Cutoff Curve

    (3) is no greater than 0.1 mm. Make sure that the upper part of the roller (4) does not collide with the control cam (3). 8. Tighten the screw (1). Service Instructions D869 e-con - 00.0 - 09/2023...
  • Page 85 (7) such that the tip of the thread-pulling knife (6) is flush with the tip of the counter blade (7). 10. Loosen the threaded pins (5) and adjust the knives. Service Instructions D869 e-con - 00.0 - 09/2023...

  • Page 86: Adjusting The Cutting Pressure

    Disturbances caused by an incorrect setting: • Increased knife wear when the pressure is too great • Problems when sewing on if the clamping pressure is too high • Problems in cutting the thread Service Instructions D869 e-con - 00.0 - 09/2023...

  • Page 87: Adjusting Point In Time For Cutting

    (2) and the widest extent of the control cam (2) is at handwheel position 60° at the highest point. 7. Tighten the threaded pins on the control cam (2). Service Instructions D869 e-con - 00.0 - 09/2023...
  • Page 88 • Insert the thread into thread-pulling knife (4) and slowly turn the handwheel. • Check the handwheel position at which the thread is cut. 9. If necessary, repeat adjustment steps 1 – 7 until the cut takes place at 60°. Service Instructions D869 e-con - 00.0 - 09/2023...

  • Page 89: Adjusting The Safety Release Clutch

    To engage the safety release clutch: 1. Tilt the machine head ( p. 18). 2. Lock the machine in place ( p. 34). 3. Hold the handwheel in place with one hand. Service Instructions D869 e-con - 00.0 - 09/2023...

  • Page 90: Adjusting The Torque

    (2) - Marking point Proper setting The machine is set at the factory such that the torque is 8 Nm when the marking point (2) is exactly above the slot (1) of the washer. Service Instructions D869 e-con - 00.0 - 09/2023...

  • Page 91: Toothed Belt

    2. Disassemble the front cover ( p. 20). 3. Disassemble the arm cover ( p. 19). 4. Disassemble handwheel and toothed belt cover ( p. 23). 5. Disassemble the motor cover ( p. 22). Service Instructions D869 e-con - 00.0 - 09/2023...
  • Page 92 • Cable thread trimmer (4) • Cable thread trimmer (5) (optional) • CAN cable (7) • Reference cable (8) • ENG-ON cable (operation lock) (9) 7. Pull the cable (11) out of the terminals. Service Instructions D869 e-con - 00.0 - 09/2023...
  • Page 93 15. Fit the tensioning roller (12). 16. Use a wrench to tension the tensioning roller (12).  It should not be possible to twist the toothed belt more than 45°. 17. Tighten the screw (13). Service Instructions D869 e-con - 00.0 - 09/2023...
  • Page 94 (9) - ENG-ON cable (operation lock) (5) - Cable thread trimmer (optional, only (10) - Holder on 2-needle machines) (11) - Cable 18. Place the holder (10) with the PCB. 19. Tighten the screws (1). Service Instructions D869 e-con - 00.0 - 09/2023...
  • Page 95 • CAN cable (7), slot X1 • Reference cable (8), slot X4 • ENG-ON cable (operation lock) (9), slot X5 21. Clamp the cable (11) into the terminals. 22. Assemble the covers. Service Instructions D869 e-con - 00.0 - 09/2023...

  • Page 96: Sewing Motor

    (4) - Toothed belt (2) - Motor (5) - Handwheel (3) - Toothed belt wheel (6) - Tensioning roller 16.2 Disassembling the sewing motor To disassemble the sewing motor: 1. Switch off the machine. Service Instructions D869 e-con - 00.0 - 09/2023...
  • Page 97 (9) - Reference cable (4) - Cable thread trimmer (10) - ENG-ON cable (operation lock) (5) - Cable thread trimmer (optional, only (11) - Holder on 2-needle machines) (12) - Cable (6) - Nut Service Instructions D869 e-con - 00.0 - 09/2023...
  • Page 98 ⑬ ⑭ (13) - Tensioning roller (14) - Screw 12. Loosen the screw (14) on the tensioning roller (13)  The toothed belt tension is slack. 13. Remove the tensioning roller (13). Service Instructions D869 e-con - 00.0 - 09/2023...
  • Page 99 15. Trace the cables (18) from the motor (19) to the control and pull the plug out of the control. 16. Loosen the screws (16) on the support plate (14). 17. Remove the support plate (17) together with the motor. Service Instructions D869 e-con - 00.0 - 09/2023...
  • Page 100 19. Pull off the toothed belt wheel (20). 20. Loosen the screws (22) on the support plate (17). 21. Pull off the motor (19) and replace it with a new one ( p. 99). Service Instructions D869 e-con - 00.0 - 09/2023...

  • Page 101: Assembling The Sewing Motor

    To assemble the sewing motor: 1. Attach the motor (4) to the support plate (1) using 4 screws (2). Make sure that the cables (5) are on the outside. 2. Fit the toothed belt wheel (3). Service Instructions D869 e-con - 00.0 - 09/2023...
  • Page 102 (1) - Support plate 5. Attach the support plate (1) along with the motor (4) using the two screws (7) on the left. Fig. 88: Assembling the sewing motor (4) ⑧ (8) - Toothed belt Service Instructions D869 e-con - 00.0 - 09/2023...
  • Page 103 7. Fit the tensioning roller (9). 8. Use a wrench to tension the tensioning roller (9).  It should not be possible to twist the toothed belt more than 45°. 9. Tighten the screw (10). Service Instructions D869 e-con - 00.0 - 09/2023...
  • Page 104 (15) - Cable thread trimmer (optional, only (21) - Holder on 2-needle machines) (22) - Cable (16) - Nut 10. Place the holder (21) with the PCB. 11. Tighten the screws (11). Service Instructions D869 e-con - 00.0 - 09/2023...
  • Page 105 16. Assemble the toothed belt cover with large handwheel ( p. 23), making sure that the centering pin is seated firmly, as the hall sensor will otherwise not be able to complete referencing properly. Service Instructions D869 e-con - 00.0 - 09/2023...
  • Page 106 Sewing motor Service Instructions D869 e-con - 00.0 - 09/2023...

  • Page 107: Programming

     This opens the navigation interface. Fig. 91: Logging in as a technician (1) ① (1) - Logout 2. Press Logout (1).  This opens the login interface. Fig. 92: Logging in as a technician (2) Service Instructions D869 e-con - 00.0 - 09/2023...

  • Page 108: Log In User

     This opens the login interface. Fig. 94: Log in user (2) There are three ways to log in. The three options - including the necessary settings in the software - are described below. Service Instructions D869 e-con - 00.0 - 09/2023...

  • Page 109: Logging In With Username And Password

    (1) - NFC chip (2) - Arm cover Assigning an NFC tag to a user To assign an NFC tag to a user: 1. Select a user in User Management or create a new user. Service Instructions D869 e-con - 00.0 - 09/2023...

  • Page 110: Login With Usb Key

    To log in with a USB key: 1. Plug the assigned USB key into the control panel.  If the USB key has been assigned correctly, the user will be logged in. Service Instructions D869 e-con - 00.0 - 09/2023...

  • Page 111: Login With File On Usb Key

    Once the user with the assigned file stored on a USB key has been created on every machine, login will be possible with a copy of the file stored on any USB key. Service Instructions D869 e-con - 00.0 - 09/2023...
  • Page 112 1. Plug the USB key holding the file into the control panel. 2. Enter username and password.  If the file on the UBS key has been assigned correctly, the user will be logged in. Service Instructions D869 e-con - 00.0 - 09/2023...

  • Page 113: Defining General Settings (Technician Access)

     This opens the navigation interface. Fig. 96: Defining general settings (1) ① (1) - Settings 2. Press Settings (1).  This opens the Settings interface. Fig. 97: Settings Service Instructions D869 e-con - 00.0 - 09/2023...
  • Page 114  p. 113 Machine Configuration  p. 150 Program defaults  p. 151 User Configuration  p. 161 Manual Data Transfer  p. 168 Service  p. 188 Information  p. 190 Software update Service Instructions D869 e-con - 00.0 - 09/2023...

  • Page 115: Setting The Machine Configuration

    Sewing foot stroke  p. 127 Stitch length  p. 129 RFW/SSD  p. 130 Needle thread monitor  p. 132 Needle thread tension sensor  p. 132 Holding force  p. 133 Pedal Service Instructions D869 e-con - 00.0 - 09/2023...
  • Page 116  p. 141 Threading mode  p. 141 Operation lock  p. 142 Manual bartack  p. 142 Jog dial  p. 142 Referencing  p. 143 Function modules  p. 143 Scanner Service Instructions D869 e-con - 00.0 - 09/2023...

  • Page 117: Setting The Thread Trimmer Parameters

    Needle position when sewing stops during 000 - 359 [°] the seam, specified in degrees • Value range Needle position after thread 000 - 359 [°] trimming Needle position after thread cutting before reversal. Service Instructions D869 e-con - 00.0 - 09/2023...
  • Page 118 00 - 99 [stitches] Number of short stitches at seam • Value range 00 - 99 [stitches] Stitch length • Value range -9.0 – 9.0 [mm] recommended value range: 0.1 – 1.5 [mm] Service Instructions D869 e-con - 00.0 - 09/2023...
  • Page 119 • Value range 000 - 359 [°] Position of the needle when the change of stitch length is deactivated. • Value range 000-359 [°] • Value range Thread trimming backward stitch On/Off Service Instructions D869 e-con - 00.0 - 09/2023...
  • Page 120 • Value range 000 - 600 [s] Duty cycle t2 Duty cycle in time period t2. • Value range 000 - 100 [%] Boost • Value range On/Off Service Instructions D869 e-con - 00.0 - 09/2023...

  • Page 121: Setting The Needle Thread Clamp Parameters

    0 = at seam beginning only 1 = seam beginning + during turn back 2 = seam beginning + during sewing foot lift 3 = seam beginning + during turn back + sewing foot lift Service Instructions D869 e-con - 00.0 - 09/2023...
  • Page 122 000 - 359 [°] Clamp For Knife Off • Value range 000 - 359 [°] Exhaust On • Value range 000 - 359 [°] Exhaust Off • Value range 00000 – 99999 [ms] Service Instructions D869 e-con - 00.0 - 09/2023...

  • Page 123: Setting The Sewing Speed Parameters

    Reduction of the speed to 3000 (rpm) in 150-9999 [rpm] combination with an activated input signal • Value range Speed limitation DB2000 Reduction of the speed to 2000 (rpm) in 150-9999 [rpm] combination with an activated input signal Service Instructions D869 e-con - 00.0 - 09/2023...

  • Page 124: Setting The Stop Positions Parameters

    000 - 359 [°] • Value range Length Pos. - Signal 000 - 359 [°] • Value range Change speed on position On/Off • Value range Position of speed change 000 - 330 [°] Service Instructions D869 e-con - 00.0 - 09/2023...

  • Page 125: Setting The Sewing Foot Lift Parameters

    Mode 2 The needle thread tension is lifted after thread cutting Mode 3 The needle thread tension is lifted as the sewing feet are lifted during sewing and after thread cutting Service Instructions D869 e-con - 00.0 - 09/2023...
  • Page 126 • Value range On/Off State After thread thread tension trimming • Value range Unchanged/Off/On State After power • Value range Unchanged/Off/On • Value range Thread tension open at service Off/On stop Service Instructions D869 e-con - 00.0 - 09/2023...

  • Page 127: Setting The Sewing Foot Stroke Parameters

    • Value range 0000 - 2800 [rpm], depending on sub- class Quick stroke adjustment in tack Setting becomes visible at a Speed level of 10 [rpm]. • Value range On/Off Service Instructions D869 e-con - 00.0 - 09/2023...
  • Page 128 • Value range 00.0 – 09.0 [mm] Max. Sewing foot stroke Sewing foot stroke at which the reduced speed is reached. • Value range 00.0 – 09.0 [mm] Service Instructions D869 e-con - 00.0 - 09/2023...

  • Page 129: Setting The Stitch Length Parameters

    MUST be adjusted subclass when changing the sewing equipment. • Value range Manual stitch length adjustment Stitch regulator for manual adjustment of On/Off the stitch length active or inactive; optional equipment. Service Instructions D869 e-con - 00.0 - 09/2023...
  • Page 130 Value range 1.0 - 9.0 [mm], depending on subclass State After thread stitch length trimming • Value range Unchanged/Off/On State After power • Value range Unchanged/Off/On Service Instructions D869 e-con - 00.0 - 09/2023...

  • Page 131: Setting The Rfw/Ssd Parameters

    SSD. • Value range 0.0 - 4.0 Values only apply to RFW Intensity the remaining thread monitor, not the SSD. • Value range 0.0 - 4.0 • Value range Sewing stop On/Off Service Instructions D869 e-con - 00.0 - 09/2023...

  • Page 132: Setting The Needle Thread Monitor Parameters

    Menu items Value range On/Off Right side Speed • Value range 0050 - 1000 [rpm] Stitch delay • Value range 000 - 255 [stitches] Debouncing • Value range 0000 – 5000 [ms] Service Instructions D869 e-con - 00.0 - 09/2023...
  • Page 133 Menu items Value range Bobbin Active • Value range On/Off Delay • Value range 0.00 - 2.55 [s] Debouncing • Value range 0.00 - 2.55 [s] • Value range Sewing stop On/Off Service Instructions D869 e-con - 00.0 - 09/2023...

  • Page 134: Setting The Needle Thread Tension Sensor Parameters

    Only visible for Mode On Max. Current Holding current of the motor • Value range 00 - 50 Only visible for Mode On Response Response time for the continuous current • Value range 000 - 100 Service Instructions D869 e-con - 00.0 - 09/2023...

  • Page 135: Setting The Pedal Parameters

    000 – 255 [ms] 17.4.14 Setting the Pedal 2 parameters If the second pedal is activated, the setting options shown will be the same as under Setting the Pedal parameters ( p. 133). Service Instructions D869 e-con - 00.0 - 09/2023...

  • Page 136: Setting The Needle Cooling Parameters

    • Value range 00.0 - 10.0 [s] Only visible for Mode Cool Speed Speed at which the needle cooling Related to sewing is activated. speed • Value range 0000 - 6000 [rpm] Service Instructions D869 e-con - 00.0 - 09/2023...

  • Page 137: Setting The Puller Parameters

    Delay when raising the roller after foot lift- 0000 – 1000 [ms] ing. Mode Setting defining which roller is supposed The upper roller runs to run. actively under power. Top + Bottom Both wheels run actively under power. Service Instructions D869 e-con - 00.0 - 09/2023...
  • Page 138 • Value range 0.0 - 5.0 [A] Diameter • Value range 0000 – 9999 [mm] Direction 0 (X) = right  ) = left Closed Loop 0 (X) = non-regulated  ) = regulated Service Instructions D869 e-con - 00.0 - 09/2023...
  • Page 139 • Value range 0.0 - 5.0 [A] Diameter • Value range 0000 – 9999 [mm] Direction 0 (X) = right  ) = left Closed Loop 0 (X) = non-regulated  ) = regulated Service Instructions D869 e-con - 00.0 - 09/2023...

  • Page 140: Setting The Edge Guide Parameters

    Smallest possible gap between the sewing 00.1 – 36.0 [mm] foot and the edge guide. The smallest possible distance depends on the sewing equipment and MUST be adapted after a change of the sewing equipment. Service Instructions D869 e-con - 00.0 - 09/2023...

  • Page 141: Setting The Material Thickness Detection Parameters

    Only visible for Fabric compensation in bartack Material thickness detection active • Value range On/Off • Value range Perfect Quality Sensor (PGS) On/Off active Service Instructions D869 e-con - 00.0 - 09/2023...

  • Page 142: Setting The Correction Speed Effect Parameters

    On: A seam is started with the pedal and then completed automati- cally at a defined sewing speed until the end of the material is detected • Value range Debouncing 0.00 - 2.55 [s] Service Instructions D869 e-con - 00.0 - 09/2023...

  • Page 143: Setting The Seam Segment Mode Parameters

    (On). • Value range Stitch length Manual stitch length adjustment with active On/Off operation lock • Value range All Inputs All inputs active during machine blockage. On/Off Service Instructions D869 e-con - 00.0 - 09/2023...

  • Page 144: Setting The Manual Bartack Parameters

    After the machine was switched on, the stepper motors need to perform a reference run. Depending on the setting, referencing can be performed automatically or by pressing the pedal back all the way. Icon Menu items Value range • Value range User start referencing manual On/Off Service Instructions D869 e-con - 00.0 - 09/2023...

  • Page 145: Setting The Function Modules Parameter

    Barcode identification active On/Off The following types of barcodes can be read using the scanner: • Code 128 • UCC EAN 128 • Code 39 The barcode types can be created with freeware software. Service Instructions D869 e-con - 00.0 - 09/2023...

  • Page 146: Setting The Rfid Scanner Parameters

    Only visible for Desk height adjustment enable • Value range Desk height Only visible for Desk height 000.0 - 140.0 adjustment enable Service Instructions D869 e-con - 00.0 - 09/2023...

  • Page 147: Setting The Interface Parameters

    DAC Flex control and at input and output modules 1 and 2. If connected correctly, any additional modules or PCBs, e.g. the stepper motor module, will appear for checking under Module management. Fig. 98: Module management Service Instructions D869 e-con - 00.0 - 09/2023...
  • Page 148  p. 141 Trigger program selection Operating Instructions Program selection Bit B0 - B9 Program selection by an external device Short stitch  p. 115 edge guide position (height)  p. 138 Service Instructions D869 e-con - 00.0 - 09/2023...
  • Page 149 Edge Guide Check Up/Down Operating Instructions Left needle bar Right needle bar Automatic stitch length adjustment Poka yoke 1-4 result Short stitch Each input can be switched to stored or not stored. Service Instructions D869 e-con - 00.0 - 09/2023...
  • Page 150 Bartacking in process Output active while bartacking is active In seam Output active while the machine is in the seam Segment Output 01 - 16 Manual bartack Push button signal Stitch done Service Instructions D869 e-con - 00.0 - 09/2023...

  • Page 151: Setting The Authentication Methods Parameters

    Allow login with file on USB key • Value range On/Off 17.4.34 Setting the Energy Saving parameter Icon Menu items Value range • Value range Energy Saving delay 0000 - 2400 [s] Service Instructions D869 e-con - 00.0 - 09/2023...

  • Page 152: Setting The Program Defaults

    • Value range -999 - 999 Stitch functions • Value range Count stitches On/Off • Value range Correction On/Off of backward stitches Service Instructions D869 e-con - 00.0 - 09/2023...

  • Page 153: Setting The User Configuration

    Abort in repair mode Direct abort 17.6 Setting the User Configuration Settings can be made here that are designed to make working on the machine in various external conditions easier for the user. Service Instructions D869 e-con - 00.0 - 09/2023...
  • Page 154 Screen configuration  Operating Manual mode Instructions Main screen configuration  Operating Manual mode Instructions Status bar configuration Role Main Screen Configuration  p. 159 Role Status Bar Configuration  p. 160 Service Instructions D869 e-con - 00.0 - 09/2023...

  • Page 155: User Management

    If, for instance, a role is derived from a Technician (default role), the new role will initially have all of the same authorizations as the original role. You will afterwards be able to adjust the authorizations for the new role using the drop-down menu. Service Instructions D869 e-con - 00.0 - 09/2023...
  • Page 156 Activate/deactivate access to the Role Status Bar function Access Activate/deactivate access to the Switch to automatic mode function Access Activate/deactivate access to the Parameter View function Access Activate/deactivate Edit the Enable bartack function Edit Service Instructions D869 e-con - 00.0 - 09/2023...
  • Page 157 Activate/deactivate Edit the Sewing foot pressure function Edit Activate/deactivate Edit the Sewing foot stroke function Edit Activate/deactivate Edit the Switch foot stroke alternation function Edit Activate/deactivate Edit the Bartack toggle function Edit Service Instructions D869 e-con - 00.0 - 09/2023...
  • Page 158 Activate/deactivate Edit the Needle thread tension correction factor function Edit Activate/deactivate Edit the Tiles enabled function Edit Sewing Activate/deactivate Edit the Enable multi functional tiles function Edit User Management Activate/deactivate Edit the Current user role Edit Service Instructions D869 e-con - 00.0 - 09/2023...
  • Page 159 Check the box to activate the user Turn the check box off to deactivate the user First name Enter the first name using the touch screen keypad Last name Enter the last name using the touch screen keypad Service Instructions D869 e-con - 00.0 - 09/2023...

  • Page 160: Smart Keys Configuration

    If assigning multiple roles to the same user, you must define one role as the primary role. The primary role is highlighted with a blue font. 17.6.2 Smart keys configuration The smart keys configuration lets you assign a function to all keys on the machine arm. Service Instructions D869 e-con - 00.0 - 09/2023...

  • Page 161: Role Main Screen Configuration

    Button Users + Role: the changes apply to the role and all users that have been assigned this role. 3. Pick the desired tile from the bar (2) and add it to the grid. Service Instructions D869 e-con - 00.0 - 09/2023...

  • Page 162: Role Status Bar Configuration

    Button Users + Role: the changes apply to the role and all users that have been assigned this role. 3. Pick the desired tile from the bar (2) and add it to the grid. Service Instructions D869 e-con - 00.0 - 09/2023...

  • Page 163: Using Manual Data Transfer

    – and a USB key. Various options are available for the data transfer, which are explained in the subchapters. 17.7.1 Exporting data To export data: 1. Connect the USB key at the control panel. 2. Press the Export button. Service Instructions D869 e-con - 00.0 - 09/2023...
  • Page 164 • 110 ORNAMENTAL SEAM Own PDFs and videos Customer Multimedia PDFs and videos from Dürkopp Vendor Multimedia Adler  The corresponding dialog appears. For example, if you have selected Programs, perform the following steps: Service Instructions D869 e-con - 00.0 - 09/2023...
  • Page 165 4. Select the export destination. E.g.: Right USB port. Abb. 107: Exporting data (2) 5. Select a program. Fig. 108: Exporting data (3) 6. Select a folder that already exists or create a new folder. Service Instructions D869 e-con - 00.0 - 09/2023...
  • Page 166 Programming Fig. 109: Exporting data (4) 7. Confirm selection. Fig. 110: Exporting data (5)  The data is exported. Service Instructions D869 e-con - 00.0 - 09/2023...

  • Page 167: Importing Data

    Appendix ( p. 230) PDFs and videos from Vendor Multimedia Dürkopp Adler Import maintenance measures Maintenance Management  The corresponding dialog appears. For example, if you have selected Programs, perform the following steps: Service Instructions D869 e-con - 00.0 - 09/2023...
  • Page 168 Fig. 111: Importing data (1) 4. Select the import source. E.g.: Right USB port. Fig. 112: Importing data (2) 5. Select the desired folder. Fig. 113: Importing data (3) 6. Select the desired program. Service Instructions D869 e-con - 00.0 - 09/2023...
  • Page 169 Programming Abb. 114: Importing data(4) 7. Confirm selection. Fig. 115: Importing data (5)  The data is imported. The machine will be restarted if necessary. Service Instructions D869 e-con - 00.0 - 09/2023...

  • Page 170: Service

     p. 175 Settings  p. 176 Multitest  p. 180 Maintenance Management  p. 183 QONDAC  p. 184 Reset  p. 185 Network  p. 185 Logging  p. 186 Logger modules Service Instructions D869 e-con - 00.0 - 09/2023...

  • Page 171: Calibration

    Only visible if the 2-axis edge guide has been activated ( p. 138)  p. 172 Pedal  p. 173 Needle thread tension  p. 175 Teach Transmission  p. 175 Reference position Service Instructions D869 e-con - 00.0 - 09/2023...
  • Page 172 Test run must be 60 mm. 5. If the test run is not the correct length, the values must be adjusted accordingly using Fig. 116: Calibration of the Feed calibration Service Instructions D869 e-con - 00.0 - 09/2023...
  • Page 173 4. Fold the edge guide down. 5. Measure the distance between the needle and the edge guide. 6. Enter the value with the -/+ buttons. 7. Confirm the entry with Next.  The calibration is complete. Service Instructions D869 e-con - 00.0 - 09/2023...
  • Page 174 3. Press the pedal halfway back to the -1 position. 4. Press Next. 5. Release the pedal (position 0). 6. Press Next. 7. Press the pedal forward to the +1 position. 8. Press Next.  Calibration complete. 9. Press Close. Service Instructions D869 e-con - 00.0 - 09/2023...
  • Page 175 4. Call up the Service > Calibration > Needle thread tension menu. 5. Adjust the needle tension to 200 cN / 500 cN / 800 cN.  The thread tension is activated, and a tick indicator is shown (e.g. 95 ticks): Service Instructions D869 e-con - 00.0 - 09/2023...
  • Page 176 Fig. 119: Calibration of the needle thread tension 7. Change the ticks ( ) until 200 cN / 500 cN / 800 cN is indicated on the scale. 8. Save the value and exit the menu. Service Instructions D869 e-con - 00.0 - 09/2023...

  • Page 177: Settings

    Service routine chapter ( p. 14) . Icon Menu item Value range Feed dog Assemble Position to needle Feed dog movement Hook-Needle Timing Needle bar Sewing foot stroke Equal sewing foot stroke Feed Move Service Instructions D869 e-con - 00.0 - 09/2023...

  • Page 178: Multi Test

    To check the inputs: 1. Press the input.  The display switches automatically to the corresponding input in the pick list on the control panel. The status (on/off) is highlighted with a color. Service Instructions D869 e-con - 00.0 - 09/2023...
  • Page 179 1. Press the pedal.  The corresponding positions or steps are displayed in the menu. Depending on the version (analog or digital), the values are displayed directly or as a status indicator (0/1). Service Instructions D869 e-con - 00.0 - 09/2023...
  • Page 180 1. Open the menu Service > Multi test > Test Material Thickness Sensor. 2. Lift the sewing feet. 3. Place the sewing material under the sewing feet. 4. Lift the sewing feet.  The signal quality (1) must display the value 1. Service Instructions D869 e-con - 00.0 - 09/2023...
  • Page 181 Counts the skip stitches for which the sensor was unable to detect a loop Value of the skip stitch Total of skip stitches counter Degree of pollution Indicates the degree of pollution. The value must be 0 on delivery. Service Instructions D869 e-con - 00.0 - 09/2023...

  • Page 182: Maintenance Management

    Logging and History, where you can view them at a later time. Fig. 122: Maintenance Management (2) ① ② (1) - Guidelines (2) - History Service Instructions D869 e-con - 00.0 - 09/2023...
  • Page 183 List of spare parts you can order which are required for the maintenance measure To create a maintenance activity: 1. Go to the Guidelines (1) section and press  A new activity with the name New Measure is created. Service Instructions D869 e-con - 00.0 - 09/2023...
  • Page 184 4. To add a description, go to the Description section, click on the icon Edit (3) and enter the text you wish to add using the touch screen keypad. 5. Add the description with a press of the button. Service Instructions D869 e-con - 00.0 - 09/2023...

  • Page 185: Qondac

    Enter the server address using Server address the touch screen keypad Information For detailed information on how to network machines, refer to the documen- tation of the QONDAC. Service Instructions D869 e-con - 00.0 - 09/2023...

  • Page 186: Reset

    Reset all data (except calibration) All parameters, programs, and calibration values are reset to the factory settings. Remove User Tutorials Remove vendor tutorials Remove log data Remove backup data Delete log files from panel and control Service Instructions D869 e-con - 00.0 - 09/2023...

  • Page 187: Network

    • Assert Data (3) • All Data • Today • Yesterday • Last two days • Last week Export (4) Export logging Reset (5) Delete logging Magnifier (6) search for specific logs Service Instructions D869 e-con - 00.0 - 09/2023...

  • Page 188: Logger Modules

    Menu item Store To USB Get last log files from control Get all log files from control Hardware drivers Operation panel Data configuration Startup measures Thread trimmer Sewing motor Pedal Machine process Bartack Service Instructions D869 e-con - 00.0 - 09/2023...
  • Page 189 Programming Icon Menu item Edge trimmer Stitch length Thread tension Foot lift Foot pressure Foot stroke Fabric sensor Speed manager Light barrier Function I/Os File operations Remote Smart bobbin winder Service Instructions D869 e-con - 00.0 - 09/2023...

  • Page 190: Information

    Icon Menu item Explanation Setting date and time Date and time Select time zone Copyright Software version Application Software version of the application Application tag Machine Software version of the connected machine Service Instructions D869 e-con - 00.0 - 09/2023...
  • Page 191 Serial number of the connected control Type of the connected control Control panel panel Machine Class selected class Machine subclass selected subclass Serial number Serial number of the machine Production date Production date of the machine Service Instructions D869 e-con - 00.0 - 09/2023...

  • Page 192: Performing A Software Update

    6. Select the desired update file.  The software update is performed. 7. Remove the USB key when the software update is complete.  The machine restarts and is ready for sewing. Service Instructions D869 e-con - 00.0 - 09/2023...

  • Page 193: Maintenance

    Servicing the pneumatic system (optional) Adjusting the operating pressure  Draining the water-oil mixture  Cleaning the filter element  Servicing specific components Cleaning the thread clamp  Checking the toothed belt  Service Instructions D869 e-con - 00.0 - 09/2023...

  • Page 194: Cleaning

    Use only solvent-free substances for cleaning. Fig. 126: Cleaning ④ ① ③ ② (1) - Area around the needle (3) - Area under the throat plate (2) - Hook (4) - Knife on the winder Service Instructions D869 e-con - 00.0 - 09/2023...

  • Page 195: Lubricating

    Oil is a pollutant and must not enter the sewage system or the soil. Carefully collect up used oil. Dispose of used oil and oily machine parts in accordance with national regulations. Service Instructions D869 e-con - 00.0 - 09/2023...

  • Page 196: Lubricating The Machine Head

    2. If the inspection glass lights up red, the machine is not sufficiently supplied with oil. 3. If the oil level is below the minimum level marking (3): Pour oil through the refill opening (1) but no higher than the maximum level marking (2). Service Instructions D869 e-con - 00.0 - 09/2023...

  • Page 197: Lubricating The Hook

    18.3.1 Adjusting the operating pressure NOTICE Property damage from incorrect adjustment! Incorrect operating pressure can result in damage to the machine. Ensure that the machine is only used when the operating pressure is set correctly. Service Instructions D869 e-con - 00.0 - 09/2023...

  • Page 198: Draining The Water-Oil Mixture

    Proper setting The water-oil mixture must not rise up to the level of the filter element (1). Check the level of the water-oil mixture in the collection tray (2). Service Instructions D869 e-con - 00.0 - 09/2023...

  • Page 199: Cleaning The Filter Element

    6. Connect the machine to the compressed air supply. 18.3.3 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. Service Instructions D869 e-con - 00.0 - 09/2023...
  • Page 200 6. Wash out the filter tray using benzine. 7. Tighten the filter element (1). 8. Tighten the collection tray (2). 9. Tighten the drain screw (3). 10. Connect the machine to the compressed air supply. Service Instructions D869 e-con - 00.0 - 09/2023...

  • Page 201: Servicing Specific Components

    4. Check the thread clamp (3) for sharp edges. If the thread clamp (3) has sharp edges: 5. Polish or change the thread clamp (3). 6. Assemble and align the thread clamp ( p. 200). Service Instructions D869 e-con - 00.0 - 09/2023...

  • Page 202: Parts List

    (3) to thread guide (6). 6. Tighten the threaded pin (5). 18.5 Parts list A parts list can be ordered from Dürkopp Adler. Or visit our website for further information at: www.duerkopp-adler.com Service Instructions D869 e-con - 00.0 - 09/2023...

  • Page 203: Decommissioning

    5. Cover the control panel to protect it from soiling. 6. Cover the control to protect it from soiling. 7. Cover the entire machine if possible to protect it from contamination and damage. Service Instructions D869 e-con - 00.0 - 09/2023...
  • Page 204 Decommissioning Service Instructions D869 e-con - 00.0 - 09/2023...

  • Page 205: Disposal

    When disposing of the machine, be aware that it consists of a range of different materials (steel, plastic, electronic components, etc.). Follow the national regulations when disposing these materials. Service Instructions D869 e-con - 00.0 - 09/2023...
  • Page 206 Disposal Service Instructions D869 e-con - 00.0 - 09/2023...

  • Page 207: Troubleshooting

    • Check wiring in machine distributor and change it, if necessary • Measure motor phases and check for value 1005 Error Motor blocked • Check for stiff movement • Replace encoder • Replace sewing motor Service Instructions D869 e-con - 00.0 - 09/2023...
  • Page 208 Information Position not reached (during bartack) • Check the controller settings and change them if necessary (e.g. thread trimmer setting, belt tension, etc.) • Check position thread lever at top dead center Service Instructions D869 e-con - 00.0 - 09/2023...
  • Page 209 Stepper card X30 init position not • Check for stiff movement found (Stitch length) • Replace encoder • Replace motor 2176 Error Stepper card X30 not enabled • Replace the control (Stitch length) Service Instructions D869 e-con - 00.0 - 09/2023...
  • Page 210 (Foot lifting) • Check selection of class 2272 Error Stepper card X40 motor overload/ • Check selection of class overvoltage/overcurrent (Foot lifting) • Replace the control • Replace encoder • Replace stepper motor Service Instructions D869 e-con - 00.0 - 09/2023...
  • Page 211 2330 Error Stepper card X50 not responding • Perform software update • Replace the control 2331 Error Stepper card X50 initialization failure • Perform software update • Check selection of class Service Instructions D869 e-con - 00.0 - 09/2023...
  • Page 212 • Replace motor 2401 Error Stepper card X60 reference drive • Check reference sensor failure (Edge guide) 2405 Error Stepper card X60 stepper motor • Check for stiff movement blockage (Edge guide) Service Instructions D869 e-con - 00.0 - 09/2023...
  • Page 213 • Check motor phase and PE for (Edge guide) low-impedance connection • Replace encoder • Replace sewing motor 2487 Error Stepper card X60 transport interval • Perform software update failure (Edge guide) • Check selection of class Service Instructions D869 e-con - 00.0 - 09/2023...
  • Page 214 Error Stepper card X70 reference drive • Check for stiff movement failure (Upper puller) • Replace encoder • Replace motor 2583 Error Stepper card X70 overcurrent • Replace the control (Upper puller) Service Instructions D869 e-con - 00.0 - 09/2023...
  • Page 215 • Replace encoder • Replace motor 2678 Error Stepper card X80 encoder failure • Replace encoder (Bottom puller) 2679 Error Stepper card X80 Current sensor • Replace the control failure (Bottom puller) Service Instructions D869 e-con - 00.0 - 09/2023...
  • Page 216 3109 Warning Operation lock • Check tilt sensor on machine 3110 Information Right thread tension magnet is not • Check the connection of right connected thread tension magnet Service Instructions D869 e-con - 00.0 - 09/2023...
  • Page 217 • Perform software update 4201 Warning Failure SD-Card • Insert SD card • Replace the control 4430 Warning OP3000: Connection lost • Check connection to OP3000 • Replace OP3000 • Replace the control Service Instructions D869 e-con - 00.0 - 09/2023...
  • Page 218 • Switch off the control, wait until (the internal data structures are not the LEDs have gone out, and then compatible with the external data switch on the control again storage device) • Software update Service Instructions D869 e-con - 00.0 - 09/2023...
  • Page 219 • Replace motor 8127 Error Stepper Puller Top encoder failure • Connect encoder cable to the control • Use correct connection 8128 Error Stepper Puller Top Current sensor • Replace the control failure Service Instructions D869 e-con - 00.0 - 09/2023...
  • Page 220 Error Stepper Puller Bottom sewing motor • Replace the control encoder not connected 8173 Error Stepper Puller Bottom sewing motor • Perform software update encoder not initialized • Check selection of class Service Instructions D869 e-con - 00.0 - 09/2023...
  • Page 221 External Edge guide X Axis (Edge guide) • Perform software update • Check selection of class 8251 Error Stepper card reference drive timeout External Edge guide Y Axis (Edge guide) • Check reference sensor Service Instructions D869 e-con - 00.0 - 09/2023...
  • Page 222 Needle Transport PCB not connected • Check connection cables • Perform software update • Replace needle transport PCB 9360 Error Edge guide pcb is not connected • Check cable • Perform software update • Replace PCB Service Instructions D869 e-con - 00.0 - 09/2023...
  • Page 223 • Reset successfully 9928 Warning Referencing? • Press pedal backwards (pedal position-2) 9929 Warning Not enough thread available • Please insert a full bobbin 9930 Warning Empty bobbin • Please insert a full bobbin Service Instructions D869 e-con - 00.0 - 09/2023...
  • Page 224 Please recalibrate the needle thread tension: • Calibrate the needle thread tension with parameter T 62 05 • Additionally on two needle machines: calibrate the left needle thread tension with parameter T 62 06 Service Instructions D869 e-con - 00.0 - 09/2023...
  • Page 225 • Thread Tension too high (Warning) 9970 Warning The limit values of the thread tension • The limit values of the thread have been exceeded too often! tension have been exceeded too often! Service Instructions D869 e-con - 00.0 - 09/2023...
  • Page 226 • Poka Yoke Function 3 The system is waiting for a release of Poka Yoke Function 3. 9981 Information • Poka Yoke Function 4 The system is waiting for a release of Poka Yoke Function 4. Service Instructions D869 e-con - 00.0 - 09/2023...

  • Page 227: Errors In Sewing Process

    Throat plate, hook or Have parts reworked by qualified spread have been specialists damaged by the needle Distance from the hook Set the correct distance ( p. 53) to the needle is not set correctly Service Instructions D869 e-con - 00.0 - 09/2023...
  • Page 228 Needle thread and hook Check threading path thread have not been threaded correctly Needle breakage Needle thickness is Use recommended needle unsuitable for the sewing thickness material or the thread Service Instructions D869 e-con - 00.0 - 09/2023...

  • Page 229: Technical Data

    (Compressed air only required in combination with optional additional equipment) Length [mm] Width [mm] Height [mm] Weight [kg] 22.2 Requirements for fault-free operation Compressed air quality must conform to ISO 8573-1: 2010 [7:4:4]. Service Instructions D869 e-con - 00.0 - 09/2023...
  • Page 230 Technical data Service Instructions D869 e-con - 00.0 - 09/2023...

  • Page 231: Appendix

    Appendix 23 Appendix 23.1 Barcode examples Fig. 134: Barcode examples Service Instructions D869 e-con - 00.0 - 09/2023...

  • Page 232: Converting Videos For Playback On The Control Panel

    Fig. 135: Converting videos (1) To convert videos for playback on the control panel: 1. Download the HandBrake program from the website handbrake.fr and install it on your computer. Fig. 136: Converting videos (2) Service Instructions D869 e-con - 00.0 - 09/2023...
  • Page 233 Fig. 138: Converting videos (4) 6. Select the Dürkopp Adler preset file DA_WebM_Handbrake_Preset.json to import it. You can obtain the preset file from Dürkopp Adler's website or from customer service. 7. Click on Open. Service Instructions D869 e-con - 00.0 - 09/2023...
  • Page 234 9. Enter the name of the video and add the file extension .webm. 10. Click on Start Encode to start encoding. Fig. 140: Converting videos (6)  The conversion process is indicated by a progress bar. Service Instructions D869 e-con - 00.0 - 09/2023...

  • Page 235: Basic Settings Of The Machine

    Required tools: • Locking peg (included in the scope of delivery, part number 0867 104950) • Spring balance 600 gr. (part number 0APP 001503) Service Instructions D869 e-con - 00.0 - 09/2023...

  • Page 236: Wiring Diagram

    Appendix 23.4 Wiring diagram Fig. 141: Wiring diagram (1) Service Instructions D869 e-con - 00.0 - 09/2023...
  • Page 237 Appendix Fig. 142: Wiring diagram (2) Service Instructions D869 e-con - 00.0 - 09/2023...
  • Page 238 Appendix Fig. 143: Wiring diagram (3) Service Instructions D869 e-con - 00.0 - 09/2023...
  • Page 239 Appendix Fig. 144: Wiring diagram (4) Service Instructions D869 e-con - 00.0 - 09/2023...
  • Page 240 Appendix Fig. 145: Wiring diagram (5) Service Instructions D869 e-con - 00.0 - 09/2023...
  • Page 241 Appendix Fig. 146: Wiring diagram (6) Service Instructions D869 e-con - 00.0 - 09/2023...
  • Page 242 Appendix Fig. 147: Wiring diagram (7) Service Instructions D869 e-con - 00.0 - 09/2023...
  • Page 243 Appendix Fig. 148: Wiring diagram (8) Service Instructions D869 e-con - 00.0 - 09/2023...
  • Page 244 Appendix Fig. 149: Wiring diagram (9) Service Instructions D869 e-con - 00.0 - 09/2023...
  • Page 245 Appendix Fig. 150: Wiring diagram (10) Service Instructions D869 e-con - 00.0 - 09/2023...
  • Page 246 Appendix Fig. 151: Wiring diagram (11) Service Instructions D869 e-con - 00.0 - 09/2023...
  • Page 247 Appendix Fig. 152: Wiring diagram (12) " Service Instructions D869 e-con - 00.0 - 09/2023...
  • Page 248 Appendix Fig. 153: Wiring diagram (13) Service Instructions D869 e-con - 00.0 - 09/2023...
  • Page 249 Appendix Fig. 154: Wiring diagram (14) Service Instructions D869 e-con - 00.0 - 09/2023...
  • Page 250 Appendix Fig. 155: Wiring diagram (15) Service Instructions D869 e-con - 00.0 - 09/2023...
  • Page 251 Appendix Fig. 156: Wiring diagram (16) Service Instructions D869 e-con - 00.0 - 09/2023...
  • Page 252 Appendix Fig. 157: Wiring diagram (17) Service Instructions D869 e-con - 00.0 - 09/2023...
  • Page 253 Appendix Fig. 158: Wiring diagram (18) Service Instructions D869 e-con - 00.0 - 09/2023...
  • Page 254 Appendix Fig. 159: Wiring diagram (19) Service Instructions D869 e-con - 00.0 - 09/2023...
  • Page 255 Appendix Fig. 160: Wiring diagram (20) Fig. 161: Wiring diagram (21) Service Instructions D869 e-con - 00.0 - 09/2023...
  • Page 256 Appendix Fig. 162: Wiring diagram (21) Service Instructions D869 e-con - 00.0 - 09/2023...
  • Page 257 Appendix Fig. 163: Wiring diagram (22) Service Instructions D869 e-con - 00.0 - 09/2023...
  • Page 258 Appendix Fig. 164: Wiring diagram (23) Service Instructions D869 e-con - 00.0 - 09/2023...
  • Page 259 Appendix Fig. 165: Wiring diagram (24) Service Instructions D869 e-con - 00.0 - 09/2023...
  • Page 260 Appendix Fig. 166: Wiring diagram (25) Service Instructions D869 e-con - 00.0 - 09/2023...
  • Page 262 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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