Duerkopp Adler 868-M PREMIUM Operating Instructions Manual
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Duerkopp Adler 868-M PREMIUM Operating Instructions Manual

Duerkopp Adler 868-M PREMIUM Operating Instructions Manual

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868-M PREMIUM
Operating Instructions

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Summary of Contents for Duerkopp Adler 868-M PREMIUM

  • Page 1 868-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 2017...

  • Page 3: Table Of Contents

    Activating function buttons ..............50 4.13.2 Assigning a function to the favorite button .......... 52 4.14 Sewing....................53 Programming ..................55 Control panel OP3000 ................. 55 Switching on the machine ..............57 Operating Instructions 868-M PREMIUM - 01.0 - 05/2017...
  • Page 4 6.3.2 Draining the water condensation ............115 6.3.3 Cleaning the filter element..............117 Parts list..................... 118 Setup ....................119 Checking the scope of delivery ............119 Removing the transport locks ............119 Operating Instructions 868-M PREMIUM - 01.0 - 05/2017...
  • Page 5 Disposal ................... 141 Troubleshooting ................143 10.1 Customer Service ................143 10.2 Messages of the software ..............143 10.3 Errors in sewing process ..............144 Technical data ................. 147 Appendix ..................151 Operating Instructions 868-M PREMIUM - 01.0 - 05/2017...
  • Page 6 Table of Contents Operating Instructions 868-M PREMIUM - 01.0 - 05/2017...

  • Page 7: About These Instructions

    Specifically, the chapter Setup  p. 119 is important for specialists. Service Instructions are supplied separately. With regard to minimum qualification and other requirements to be met by personnel, please also follow the chapter Safety ( p. 9). Operating Instructions 868-M PREMIUM - 01.0 - 05/2017...

  • Page 8: Representation Conventions - Symbols And Characters

    Lists are marked by bullet points.  Result of performing an operation Change to the machine or on the display/control panel. Important Special attention must be paid to this point when performing a step. Operating Instructions 868-M PREMIUM - 01.0 - 05/2017...

  • Page 9: Other Documents

    Each manufacturer has performed a hazard assessment for these purchased parts and confirmed their design compliance with ap- plicable European and national regulations. The proper use of the built-in components is described in the corresponding manufac- turer's instructions. Operating Instructions 868-M PREMIUM - 01.0 - 05/2017...

  • Page 10: Liability

    This will ensure any claims against the transport company. Report all other complaints to Dürkopp Adler immediately after receiving the product. Operating Instructions 868-M PREMIUM - 01.0 - 05/2017...

  • Page 11: Safety

    The power plug may only be assembled to the power cable by qualified specialists. Obligations Follow the country-specific safety and accident prevention regu- of the operator lations and the legal regulations concerning industrial safety and the protection of the environment. Operating Instructions 868-M PREMIUM - 01.0 - 05/2017...

  • Page 12: Signal Words And Symbols Used In Warnings

    Signal words Signal words and the hazard they describe: Signal word Meaning DANGER (with hazard symbol) If ignored, fatal or serious injury will result WARNING (with hazard symbol) If ignored, fatal or serious injury can result Operating Instructions 868-M PREMIUM - 01.0 - 05/2017...
  • Page 13 NOTICE (without hazard symbol) If ignored, property damage can result Symbols The following symbols indicate the type of danger to personnel: Symbol Type of danger General Electric shock Puncture Crushing Environmental damage Operating Instructions 868-M PREMIUM - 01.0 - 05/2017...
  • Page 14 Consequences of non-compliance. Measures for avoiding the danger.  This is what a warning looks like for a hazard that could result in moderate or minor injury if the warning is ignored. Operating Instructions 868-M PREMIUM - 01.0 - 05/2017...
  • Page 15 Type and source of danger! Consequences of non-compliance. Measures for avoiding the danger.  This is what a warning looks like for a hazard that could result in environmental damage if ignored. Operating Instructions 868-M PREMIUM - 01.0 - 05/2017...
  • Page 16 Safety Operating Instructions 868-M PREMIUM - 01.0 - 05/2017...

  • Page 17: Machine Description

    (1) - Electronically regulated (4) - Oil level indicator thread tension (ETT) (5) - Winder (2) - Push buttons (6) - Electronic handwheel (3) - Stitch adjustment lever (7) - Control panel OP3000 Operating Instructions 868-M PREMIUM - 01.0 - 05/2017...

  • Page 18: Proper Use

    DIN EN 60204-31. Only authorized persons may work on the machine. Dürkopp Adler cannot be held liable for damages resulting from improper use. Operating Instructions 868-M PREMIUM - 01.0 - 05/2017...

  • 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 - 01.0 - 05/2017...
  • Page 20 Machine description Operating Instructions 868-M PREMIUM - 01.0 - 05/2017...

  • Page 21: Operation

    Complete the following steps in preparation of sewing before starting to work: • Inserting/changing the needle • Threading the needle thread • Inserting and winding on the hook thread • Setting the thread tensions Operating Instructions 868-M PREMIUM - 01.0 - 05/2017...

  • Page 22: Switching On And Off The Machine

     The indicator LED (1) and the POWER LED (3) illuminate. Switching off the machine To switch off the machine: Set the main switch (2) to position 0. The indicator LED (1) and the POWER LED (3) go out. Operating Instructions 868-M PREMIUM - 01.0 - 05/2017...

  • Page 23: Switching On And Off The Sewing Lamp

    Press button (2) if the sewing lamp is not yet illuminated. Switching off the dimmable sewing lamp To switch off the dimmable sewing lamp: Set switch (1) or main switch (3) to position O.  The dimmable sewing lamp goes out. Operating Instructions 868-M PREMIUM - 01.0 - 05/2017...

  • Page 24: Inserting/Changing The Needle

    There is a risk of machine damage, needle breakage or thread breakage if the distance between needle and hook tip is incorrect. Check the distance to the hook tip after inserting a needle with a different thickness. Operating Instructions 868-M PREMIUM - 01.0 - 05/2017...

  • Page 25: In 1-Needle Machines

    Align the new needle in such a way that the groove (3) faces the hook. Tighten the screw (2). Order Always adjust the clearance between the hook and the needle after changing to a different needle thickness ( Service Instructions). Operating Instructions 868-M PREMIUM - 01.0 - 05/2017...

  • Page 26: In 2-Needle Machines

    To change the right needle, loosen the right screw (2). To change the left needle, loosen the left screw (2). Pull the needles downwards out of the needle holder (4). Operating Instructions 868-M PREMIUM - 01.0 - 05/2017...
  • Page 27 An incorrect hook distance can cause the following disturbances: • Changing to a thinner needle: • Missing stitches • Thread damage • Changing to a thicker needle: • Damage to the hook tip • Damage to the needle Operating Instructions 868-M PREMIUM - 01.0 - 05/2017...

  • Page 28: Threading The Needle Thread

    The thread guide (2) must stand directly above the thread reel. Feed the thread from the rear to the front to the hose guide (1). Use compressed air to blow the thread through the hose guide (1). Operating Instructions 868-M PREMIUM - 01.0 - 05/2017...
  • Page 29 (5) - Spring tip (10) - Pre-tensioner (6) - Thread tension spring (11) - Tensioner (7) - Tightening lever Feed the thread clockwise from the hose guide (1) around the pre-tensioner (10). Operating Instructions 868-M PREMIUM - 01.0 - 05/2017...
  • Page 30 ⑯ (12) - Thread lever (15) - Lower thread guide (13) - Upper thread guide of the thread clamp (14) - Upper thread guide (16) - Thread clamp of the thread clamp Operating Instructions 868-M PREMIUM - 01.0 - 05/2017...
  • Page 31 The thread is supposed to run through the thread clamp almost without touching it and in such a way that it only makes contact with the thread guides above and below the thread clamp. Operating Instructions 868-M PREMIUM - 01.0 - 05/2017...
  • Page 32 If the loose thread end is too long, the thread may be caught by the hook and cause a disturbance. If the loose thread end is too short, the machine cannot start sewing. Operating Instructions 868-M PREMIUM - 01.0 - 05/2017...

  • Page 33: In 2-Needle Machines

    (2). Feed the left thread from the rear to the front to the left hose guide (1). Use compressed air to blow both threads through the hose guides (1) and (2). Operating Instructions 868-M PREMIUM - 01.0 - 05/2017...
  • Page 34 (9) - Pre-tensioner (5) - Thread tension spring (right needle thread) (6) - Tightening lever (10) - Tensioner (right needle thread) (7) - Thread guide (right needle thread) (8) - Tensioner (right needle thread) Operating Instructions 868-M PREMIUM - 01.0 - 05/2017...
  • Page 35 11. Feed the thread clockwise from the left hose guide (1) around the pre-tensioner (13). 12. Feed the thread counterclockwise around the tensioner (12). 13. Feed the thread clockwise around the tensioner (14). Operating Instructions 868-M PREMIUM - 01.0 - 05/2017...
  • Page 36 21. Thread the right thread from the right through the lower hole on the thread lever (15). 22. Thread the left thread from the right through the upper hole on the thread lever (15). Operating Instructions 868-M PREMIUM - 01.0 - 05/2017...
  • Page 37 27. Insert the right thread through the right hole of the guide below the thread clamp (19). 28. Insert the left thread through the left hole of the guide below the thread clamp (19). Operating Instructions 868-M PREMIUM - 01.0 - 05/2017...
  • Page 38 If the loose thread end is too long, the thread may be caught by the hook and cause a disturbance. If the loose thread end is too short, the machine cannot start sewing. Operating Instructions 868-M PREMIUM - 01.0 - 05/2017...

  • Page 39: Winding The Hook Thread

    The unwinding bracket must stand directly above the thread reel. Insert the thread from the rear to the front through the unwind- ing bracket (2). Use compressed air to blow the thread through the hose guide (1). Operating Instructions 868-M PREMIUM - 01.0 - 05/2017...
  • Page 40 Fig. 19: Winding the hook thread (3) ⑨ ⑧ ⑦ (7) - Bobbin lever (9) - Cutter (8) - Bobbin shaft Clamp the thread behind the cutter (9) and tear off the loose end behind it. Operating Instructions 868-M PREMIUM - 01.0 - 05/2017...
  • Page 41 The cutter is automatically moved into its basic vertical position. 13. Pull off the full bobbin. 14. Tear off the thread behind the cutter (9). 15. Insert the full bobbin into the hook ( p. 40). Operating Instructions 868-M PREMIUM - 01.0 - 05/2017...

  • Page 42: Changing The Bobbin

    (8) light up on the machine arm. The left light is for the left-hand hook, and the right light is for the right-hand hook. Fig. 20: Changing the right bobbin (1-needle and 2-needle machines) (2) ⑧ (10) - LEDs Operating Instructions 868-M PREMIUM - 01.0 - 05/2017...
  • Page 43 Remove the empty bobbin (6). Insert a full bobbin (6): Important Insert the bobbin (6) so that the bobbin (6) moves in the opposite direction of the hook when the thread is pulled out. Operating Instructions 868-M PREMIUM - 01.0 - 05/2017...
  • Page 44 The left hook has the same design as the right hook, but is rotated by 180°. To change the left bobbin: Change the left bobbin following the same order as for the right bobbin ( p. 41). Operating Instructions 868-M PREMIUM - 01.0 - 05/2017...

  • Page 45: Thread Tension

    (3) - Needle thread tension higher than hook thread tension 4.8.1 Setting the needle thread tension The needle thread tension can only be set using the software of the OP3000; for detailed information, refer to the chapter Programming ( p. 55). Operating Instructions 868-M PREMIUM - 01.0 - 05/2017...

  • Page 46: Setting The Hook Thread Tension

    The hook thread tension is generated by the tension spring (1) and adjusted via the screw (2). To set the hook thread tension: Increasing the hook thread tension Turn screw (2) clockwise. Reducing the hook thread tension Turn screw (2) counterclockwise. Operating Instructions 868-M PREMIUM - 01.0 - 05/2017...

  • Page 47: Setting The Needle Thread Regulator

    • To increase the tension: Slide the needle thread regulator (1) to the right • To reduce the tension: Slide the needle thread regulator (1) to the left Tighten the screw (2). Operating Instructions 868-M PREMIUM - 01.0 - 05/2017...

  • Page 48: In 2-Needle Machines

    • To increase the tension: Slide the needle thread regulator (4) to the right. • To reduce the tension: Slide the needle thread regulator (4) to the left. Tighten the screw (3). Operating Instructions 868-M PREMIUM - 01.0 - 05/2017...

  • Page 49: Lifting The Sewing Feet

    The sewing feet remain up as long as the pedal is pressed halfway back. Press the pedal (1) fully back.  The thread cutter is activated, and the sewing feet are raised. Operating Instructions 868-M PREMIUM - 01.0 - 05/2017...

  • Page 50: Sewing Backwards With The Stitch Adjustment Lever (Optional)

    (1) - Stitch adjustment lever Slowly push the stitch adjustment lever (1) down.  The stitch length becomes smaller. In the lower end position, the machine sews backwards with the set stitch length. Operating Instructions 868-M PREMIUM - 01.0 - 05/2017...

  • Page 51: Setting Quick Stroke Adjustment

     The elevated sewing foot stroke is retained as long as the knee button is pushed to the right. • To switch off the elevated sewing foot stroke: Release the knee button (1). Operating Instructions 868-M PREMIUM - 01.0 - 05/2017...

  • Page 52: Quick Functions On The Push Buttons

    Press the desired button again.  Function is deactivated. The button turns off. Information The function buttons can be expanded by an additional button. The button can be assigned 2 additional functions. Operating Instructions 868-M PREMIUM - 01.0 - 05/2017...
  • Page 53 Fully customizable The button is fully customizable. The machine comes configured so that the machine will switch to the next seam section when the button is pressed. Operating Instructions 868-M PREMIUM - 01.0 - 05/2017...

  • Page 54: Assigning A Function To The Favorite Button

    Turn all screws to their initial position (3) so that the slots of the screws are horizontal. Turn the screw (2) under the desired button 90° so that the slot is vertical (4). Operating Instructions 868-M PREMIUM - 01.0 - 05/2017...

  • Page 55: Sewing

    • Press the pedal halfway back (position -1) The sewing feet are lifted. sewing material • Position the sewing material. • Release the pedal. Sewing feet are lowered onto the sewing material. At seam beginning Operating Instructions 868-M PREMIUM - 01.0 - 05/2017...
  • Page 56 • Press the pedal fully back (position -2) and keep it and remove the there. End bartack is sewn, and thread is cut (if set). sewing material Machine stops. Needle is up. Sewing feet up. • Remove the sewing material. Operating Instructions 868-M PREMIUM - 01.0 - 05/2017...

  • Page 57: Programming

    Control panel OP3000 Fig. 33: Control panel ① ② (1) - Softkey button (2) - Softkey menu button All settings in the software for the 868-M PREMIUM are performed using the OP3000 control panel. Button Function Numeric • Inputting the parameter value...
  • Page 58 Display on the control panel The display shows the menu items that can be selected. The activated menu point is shown inverted. Fig. 34: The active entry is shown inverted (example) 4 +000 +00 -013 Operating Instructions 868-M PREMIUM - 01.0 - 05/2017...

  • Page 59: Switching On The Machine

    Switching on the machine Fig. 35: Switching on the machine ① (1) - Main switch To switch on the machine: Switch on the main switch (1).  The display briefly shows the software versions: Operating Instructions 868-M PREMIUM - 01.0 - 05/2017...
  • Page 60 The display shows the program last used, or Manual mode. Fig. 37: Display of the program last used (Automatic mode) 4 +000 +00 -013 Fig. 38: Display in Manual mode 5 3.0 Operating Instructions 868-M PREMIUM - 01.0 - 05/2017...

  • Page 61: Software Operating Modes

    Programming Software operating modes The software of the 868-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

    Stitch length Value range: 00.0 – 12.0 [mm] (depending on the sewing equipment and subclass) • Use ◄/► to select the Stitch length parameter • Use ▲/▼ to change the stitch length Operating Instructions 868-M PREMIUM - 01.0 - 05/2017...
  • Page 63 • Edge stop (Edge Guide) ( p. 76) • Correcting effects of high speed (Speed Corr.) ( p. 76) • Material thickness detection (Fabric Thickness) ( p. 81) • Light barrier (LightBarrier) ( p. 87) Operating Instructions 868-M PREMIUM - 01.0 - 05/2017...

  • Page 64: Selecting The Quick Access Function (Softkey Menu)

    Here, you have quick access to functions during the sewing pro- cess. You can also assign a function to the softkey button. To select a quick access function: Press the softkey menu button. The following display appears: Operating Instructions 868-M PREMIUM - 01.0 - 05/2017...
  • Page 65 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. Operating Instructions 868-M PREMIUM - 01.0 - 05/2017...
  • Page 66 Moves the position for the 2nd 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. Operating Instructions 868-M PREMIUM - 01.0 - 05/2017...
  • Page 67 Moves 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. Operating Instructions 868-M PREMIUM - 01.0 - 05/2017...

  • Page 68: Setting The Speed Parameter (Max. Speed)

    Menu item Setting option (Thread Clamp) ON = on Thread clamp OFF = off Operating Instructions 868-M PREMIUM - 01.0 - 05/2017...

  • Page 69: Setting The Initial Alignment Stitch Parameter (Pointpos.°)

    Number of sections in a bartack  p. 69 Value range t Change, Waiting time at turning 0000 – 1000 [ms] points  p. 69 ON/OFF St.Len.Def., Default stitch length  p. 69 Operating Instructions 868-M PREMIUM - 01.0 - 05/2017...
  • Page 70 Value range 01 - 50 ON/OFF First Repet, Number of stitches different for 1 section  p. 69 Stitches (↑/↓) Value range 01 - 50 ON/OFF Invert Dir., Invert direction  p. 70 Operating Instructions 868-M PREMIUM - 01.0 - 05/2017...
  • Page 71 Only the number of forward and backward stitches can be select- ed. The stitch length cannot be set individually – it corresponds to the stitch length of the normal start bartack. Setting: Number of stitches different for 1 section Operating Instructions 868-M PREMIUM - 01.0 - 05/2017...

  • Page 72: Set End Bartack Parameter (End Tack)

    Number of sections in a bartack  p. 69 Value range t Change, Waiting time at turning 0000 – 1000 [ms] points  p. 69 ON/OFF St.Len.Def., Default stitch length  p. 69 Operating Instructions 868-M PREMIUM - 01.0 - 05/2017...
  • Page 73 Number of stitches different for last section  p. 71 Stitches (↑/↓) Value range 01 - 50 ON/OFF Invert Dir., Invert direction  p. 70 Setting: Number of stitches different for last section Operating Instructions 868-M PREMIUM - 01.0 - 05/2017...

  • Page 74: Setting The Sewing Foot Lift Parameter (Foot)

    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. Operating Instructions 868-M PREMIUM - 01.0 - 05/2017...
  • Page 75 If the parameter is not activated, only the LEDs on the machine arm give a warning if the bobbin is empty. Operating Instructions 868-M PREMIUM - 01.0 - 05/2017...
  • Page 76 LEDs on the machine arm give a warning if the bobbin is empty. It is only possible to resume sewing after ResetNeces ON/OFF changing the bobbin and confirming the message on the control panel. Operating Instructions 868-M PREMIUM - 01.0 - 05/2017...

  • Page 77: Setting The Information Parameter (Info)

    Menu item Meaning no display Pedal position Pedal (Value range 24 – -2) Material thickness detection Thick Handwheel position (Value range 000 – 359 [°]) Current speed Speed Bobbin stitch counter Bobbin Operating Instructions 868-M PREMIUM - 01.0 - 05/2017...

  • Page 78: Setting The Edge Stop Parameter (Edge Guide)

    Menu items Setting option 1 Setting option 2 ON/OFF Stitchlen., Stitch length  p. 79 linear Stitchlen. Min. speed Max. speed 2.OnOff Min. speed 2.On Min. speed Operating Instructions 868-M PREMIUM - 01.0 - 05/2017...
  • Page 79 Thr.Tens., Needle thread tension  p. 80 linear Thr.Tens. Min. speed Max. speed 2.OnOff Min. speed 2.On Min. speed FootPress., Sewing foot pressure  p. 80 linear FootPress. Min. speed Max. speed Operating Instructions 868-M PREMIUM - 01.0 - 05/2017...
  • Page 80 DOES NOT switch to the base value for the parameter. Only after finishing the seam by cutting the thread is the base value for the param- eter set again. Operating Instructions 868-M PREMIUM - 01.0 - 05/2017...
  • Page 81 0000 – 4000 [rpm] (depending on subclass) Speed from which the 2 stitch 2.On Min. speed Value range length should be used. 0000 – 4000 [rpm] (depending on subclass) Operating Instructions 868-M PREMIUM - 01.0 - 05/2017...
  • Page 82 0000 – 4000 [rpm] should start. (depending on subclass) Speed up to which the Max. speed Value range increase in sewing foot 0000 – 4000 [rpm] pressure should occur. (depending on subclass) Operating Instructions 868-M PREMIUM - 01.0 - 05/2017...

  • Page 83: Setting The Material Thickness Detection Parameter (Fabric Thickness)

    Stroke ThickMin ThickMax 2.OnOff ThickMin 2.On ThickMin Stitchlen., Stitch length  p. 85 linear Stitchlen. ThickMin ThickMax 2.OnOff ThickMin 2.On ThickMin Thr.Tens., Needle thread tension  p. 86 linear Thr.Tens. ThickMin ThickMax Operating Instructions 868-M PREMIUM - 01.0 - 05/2017...
  • Page 84 Menu items Setting option 1 Setting option 2 2.OnOff ThickMin 2.On ThickMin FootPress., Sewing foot pressure  p. 86 linear FootPress. ThickMin ThickMax Max.Speed, Speed  p. 86 linear Max.Speed ThickMin ThickMax Operating Instructions 868-M PREMIUM - 01.0 - 05/2017...
  • Page 85 DOES NOT switch to the base value for the parameter. Only after finishing the seam by cutting the thread is the base value for the parameter set again. Operating Instructions 868-M PREMIUM - 01.0 - 05/2017...
  • Page 86 Value range 00.0 – 10.0 [mm] which the 2 sewing foot stroke height should be used. Material thickness from 2.On ThickMin Value range 00.0 – 10.0 [mm] which the 2 sewing foot stroke height should be used. Operating Instructions 868-M PREMIUM - 01.0 - 05/2017...
  • Page 87 Value range 00.0 – 10.0 [mm] which the 2 stitch length should be used. Material thickness from 2.On ThickMin Value range 00.0 – 10.0 [mm] which the 2 stitch length should be used. Operating Instructions 868-M PREMIUM - 01.0 - 05/2017...
  • Page 88 Value range 00.0 – 10.0 [mm] the increase in sewing foot pressure should start. Material thickness up to ThickMax Value range 00.0 – 10.0 [mm] which the increase in sewing foot pressure should occur. Operating Instructions 868-M PREMIUM - 01.0 - 05/2017...

  • Page 89: Setting The Light Barrier (Lightbarrier) Parameter

    The signal scan of the light barrier is performed at the end of the seam. If the function is active, the machine will continue to sew with the specifically set parameters following the signal detection. If the function is inactive, nothing will happen. Operating Instructions 868-M PREMIUM - 01.0 - 05/2017...
  • Page 90 To prevent this from happening, you enter the number of filter stitches. This number represents the minimum number of stitches with signal detection following the 1st detection of the signal. Operating Instructions 868-M PREMIUM - 01.0 - 05/2017...

  • Page 91: Using Automatic Mode

    0 – 9 and confirm with the OK button If you select program 000, the control selects Manual mode,  p. 60. Seam sections Number of seam sections contained in the current program. Operating Instructions 868-M PREMIUM - 01.0 - 05/2017...

  • Page 92: Sewing In Automatic Mode

    The number under the current seam section shows the number of stitches yet to be sewn / the outstanding length of the seam section. The program bar shows half the current seam section in bold. Operating Instructions 868-M PREMIUM - 01.0 - 05/2017...
  • Page 93 Technician level. The s.p.m. option is set at the factory. Stop at the end of the seam section with thread cutting Switch between two seam sections without stopping Switch between two seam sections, with a stop, but without thread cutting Operating Instructions 868-M PREMIUM - 01.0 - 05/2017...

  • Page 94: Canceling A Program In Automatic Mode

    To cancel the program completely, press the pedal all the way backwards again.  The program is canceled, and the machine starts from the first seam section in the program when sewing resumes. Operating Instructions 868-M PREMIUM - 01.0 - 05/2017...

  • Page 95: Using Programming/Edit Mode

    Fig. 47: Programming mode display Programming mode offers two options for creating new seam programs: • Creating a program using keyboard input,  p. 94. • Creating a program using teach-in,  p. 96. Operating Instructions 868-M PREMIUM - 01.0 - 05/2017...

  • Page 96: Creating A Program Using Keyboard Input

    Stitch length for the current seam section Value range: 00.0 – 12.0 [mm] (depending on subclass) • Use ◄/► to select the Stitch length parameter • Use ▲/▼ to change the stitch length Operating Instructions 868-M PREMIUM - 01.0 - 05/2017...
  • Page 97 Repeat steps 6 and 7 to define up to 30 seam sections if necessary. Press the ESC button.  The program is saved. The machine switches to Automatic mode and the newly created program is selected. Operating Instructions 868-M PREMIUM - 01.0 - 05/2017...

  • Page 98: Creating A Program Using Teach-In

    Stitch length for the current seam section Value range: 00.0 – 12.0 [mm] (depending on subclass) • Use ◄/► to select the Stitch length parameter • Use ▲/▼ to change the stitch length Operating Instructions 868-M PREMIUM - 01.0 - 05/2017...
  • Page 99 Push the pedal fully back.  The program switches to Edit mode. If necessary, set additional parameters for all seam sections ( p. 98) and complete the selected program ( p. 100). Operating Instructions 868-M PREMIUM - 01.0 - 05/2017...

  • Page 100: Adjusting Parameters For The Current Seam Section

    Parameters for the current seam section: Symbol Description StitchCount Length of the seam section 0 = Manually step through > 1 = Number of stitches or length in mm Max. speed Maximum speed for the seam section. Operating Instructions 868-M PREMIUM - 01.0 - 05/2017...
  • Page 101 Seam middle guide (only on 2-needle machines) Edge Guide • Gap Edge stop (if available); value for the distance between the needle and the material edge, setting identical to Manual mode,  p. 76. Operating Instructions 868-M PREMIUM - 01.0 - 05/2017...

  • Page 102: Adjusting Parameters For The Selected Program

    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. Operating Instructions 868-M PREMIUM - 01.0 - 05/2017...
  • Page 103 Daily piece counter, can be set to count either up or down. When the daily piece counter is activated, it must be reset once after entering a value using the function in the softkey menu to ensure it counts correctly. Operating Instructions 868-M PREMIUM - 01.0 - 05/2017...

  • Page 104: Editing Programs

    Press the P button.  The control switches to Edit mode. The following information is shown, and the P in the program number field flashes: Fig. 50: Display in editing mode 5 2.0 Operating Instructions 868-M PREMIUM - 01.0 - 05/2017...

  • Page 105: Copying The Program

     The P above the program number will flash. Press the softkey menu button.  The softkey menu appears. Fig. 51: Softkey menu Press the numeric button under  The following display appears: Operating Instructions 868-M PREMIUM - 01.0 - 05/2017...
  • Page 106 5 2.0 If necessary, make changes to the newly copied program. Press the ESC button.  The program is saved. The machine switches to Automatic mode and the newly created program is selected. Operating Instructions 868-M PREMIUM - 01.0 - 05/2017...

  • Page 107: Deleting The Program

    ▲/▼ To delete further programs, select the program using repeat from step 3. Press the ESC button to go to Automatic mode.  The machine switches to Automatic mode. Operating Instructions 868-M PREMIUM - 01.0 - 05/2017...
  • Page 108 Programming Operating Instructions 868-M PREMIUM - 01.0 - 05/2017...

  • Page 109: Maintenance

    Advanced maintenance work may only be carried out by qualified specialists ( Service Instructions). Maintenance interval Work to be carried out Operating hours Cleaning  Removing lint and thread remnants Lubricating  Lubricating the machine head  Lubricating the hook Operating Instructions 868-M PREMIUM - 01.0 - 05/2017...

  • Page 110: Cleaning

    Make sure no particles fly into the oil pan. NOTICE Property damage from soiling! Lint and thread remnants can impair the operation of the machine. Clean the machine as described. Operating Instructions 868-M PREMIUM - 01.0 - 05/2017...
  • Page 111 ③ ② (1) - Area around the needle(s) (3) - Area under the throat plate (2) - Area around the hook Fig. 56: Cleaning (2) ⑤ (4) - Cutter on the winder Operating Instructions 868-M PREMIUM - 01.0 - 05/2017...

  • Page 112: Lubricating

    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. Only use oil that complies with the data in the instructions. Operating Instructions 868-M PREMIUM - 01.0 - 05/2017...
  • Page 113 • Flash point: 150 °C You can order the lubricating oil from our sales offices using the following part numbers. Container Part no. 250 ml 9047 000011 9047 000012 9047 000013 9047 000014 Operating Instructions 868-M PREMIUM - 01.0 - 05/2017...

  • Page 114: Lubricating The Machine Head

    Only lubricate the hook when the machine is switched off. Carry out function tests with utmost caution when the sewing machine is switched on. The approved oil quantity for hook lubrication is a factory specification. Operating Instructions 868-M PREMIUM - 01.0 - 05/2017...
  • Page 115 • clockwise: less oil is released Important The released amount of oil does not change until the operating time has run a few minutes. Sew for several minutes before you check the setting again. Operating Instructions 868-M PREMIUM - 01.0 - 05/2017...

  • Page 116: Servicing The Pneumatic System

    The operating pressure cannot deviate by more than ± 0.5 bar. Check the operating pressure on a daily basis. Fig. 59: Setting the operating pressure ① ② (1) - Pressure controller (2) - Pressure gage Operating Instructions 868-M PREMIUM - 01.0 - 05/2017...

  • Page 117: Draining The Water Condensation

    Water condensation accumulates in the water separator (2) of the pressure controller. Proper setting Water condensation must not rise up to the level of the filter element (1). Check the water level in the water separator (2) on a daily basis. Operating Instructions 868-M PREMIUM - 01.0 - 05/2017...
  • Page 118 Place the collection tray under the drain screw (3). Loosen the drain screw (3) completely. Allow water to drain into the collection tray. Tighten the drain screw (3). Connect the machine to the compressed air supply. Operating Instructions 868-M PREMIUM - 01.0 - 05/2017...

  • Page 119: Cleaning The Filter Element

    Loosen the water separator (2). Loosen the filter element (1). Blow out the filter element (1) using a compressed air gun. Wash out the filter tray using benzine. Tighten the filter element (1). Operating Instructions 868-M PREMIUM - 01.0 - 05/2017...

  • Page 120: Parts List

    Tighten the drain screw (3). 10. Connect the machine to the compressed air supply. Parts list A parts list can be ordered from Dürkopp Adler. Or visit our website for further information at: www.duerkopp-adler.com Operating Instructions 868-M PREMIUM - 01.0 - 05/2017...

  • Page 121: Setup

    Remove all transport locks before setting up the machine: • Lashing straps and wooden blocks from the machine head, the table and the stand • Supporting wedges between machine arm and throat plate • all cardboard and Styrofoam pieces Operating Instructions 868-M PREMIUM - 01.0 - 05/2017...

  • Page 122: Assembling The Stand

    Important: Turn the adjusting screw (3) so that the stand has even contact with the ground. * Stand components for long arm machines have 2 cross bars, and the other stand components have 1 cross bar. Operating Instructions 868-M PREMIUM - 01.0 - 05/2017...

  • Page 123: Assembling The Pedal And Setpoint Device

    Attach the pedal rod (1) with the ball sockets to the setpoint device (5) and to the pedal (4). Pull the pedal rod (1) to the correct length: Proper setting 10° inclination with pedal (4) released Tighten the screw (2). Operating Instructions 868-M PREMIUM - 01.0 - 05/2017...

  • Page 124: Tabletop

    (6) - Hole (3) - Drawer (7) - Reel stand (4) - Oil pan To complete the tabletop: Screw the drawer (3) with the left-hand bracket to the under- side of the tabletop. Operating Instructions 868-M PREMIUM - 01.0 - 05/2017...

  • Page 125: Assembling The Tabletop To The Stand

    To assemble the tabletop to the stand: Place the tabletop on the head sections (1) of the inner bars. Use the screws (2) to fasten the tabletop at the screw holes of the head sections. Operating Instructions 868-M PREMIUM - 01.0 - 05/2017...

  • Page 126: Setting The Working Height

    The working height is continuously adjustable between 750 and 900 mm (clearance between the floor and upper edge of the tabletop). Fig. 66: Setting the working height ① (1) - Screws Operating Instructions 868-M PREMIUM - 01.0 - 05/2017...

  • Page 127: Assembling The Control

    Screw the control (2) onto the 4 screw holders (3) under the tabletop. Clamp the power cable of the control (2) into the strain relief mechanism (1). Screw the strain relief mechanism (1) under the tabletop. Operating Instructions 868-M PREMIUM - 01.0 - 05/2017...

  • Page 128: Inserting The Machine Head

    • To set up the machine head (2) straight: Tighten the hinges (1) at the topmost position. Fig. 68: Inserting the machine head (1) ② ① (1) - Hinge (2) - Machine head Operating Instructions 868-M PREMIUM - 01.0 - 05/2017...
  • Page 129 Insert the machine head (2) from above at an angle of 45°. Insert the hinges (1) into the rubber inlays (3). Tilt the machine head (2) forward and insert it into the slot in the tabletop. Operating Instructions 868-M PREMIUM - 01.0 - 05/2017...

  • Page 130: Assembling The Control Panel

    Use the tilt protection devices (4) to secure the machine head at the hinges (1). Assembling the control panel Fig. 72: ① ② ② (1) - Control panel (3) - Bracket (2) - Plug Operating Instructions 868-M PREMIUM - 01.0 - 05/2017...

  • Page 131: Assembling The Knee Button

    Guide the connecting cable (2) to the back between the oil pan and the control. Insert the plug (3) of the connecting cable into the socket of the control. Operating Instructions 868-M PREMIUM - 01.0 - 05/2017...

  • Page 132: Assembling The Oil Extraction Line

    Insert the tube (1) of the oil extraction line into the plastic adapter. 7.12 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. Operating Instructions 868-M PREMIUM - 01.0 - 05/2017...

  • Page 133: Connecting The Sewing Lamp Transformer

    (1) - Sewing lamp transformer Assembling the sewing lamp transformer Screw the sewing lamp transformer (1) in place at the pre- drilled holes under the tabletop. Assemble the connecting cable under the tabletop using cable ties. Operating Instructions 868-M PREMIUM - 01.0 - 05/2017...
  • Page 134 Loosen the adapter cover screws (2). Connect the supply line: • for additional sewing lamps to be assembled to the X3 port (5) • for integrated LED sewing lamps connected to the 24V/X5 port (4) Operating Instructions 868-M PREMIUM - 01.0 - 05/2017...

  • Page 135: Establishing Equipotential Bonding

    Feed the equipotential bonding cable from the connection (1) on the rear side of the control through the slot in the tabletop and plug it onto the tab connector (2) on the base plate. Operating Instructions 868-M PREMIUM - 01.0 - 05/2017...

  • Page 136: Connecting The Control

    The pneumatic system of the machine and of the additional equip- ment must be supplied with dry and oil-free compressed air. The supply pressure must lie between 8 and 10 bar. Operating Instructions 868-M PREMIUM - 01.0 - 05/2017...

  • Page 137: Assembling The Compressed Air Maintenance Unit

    Connect the machine hose (4) coming out of the machine head to the maintenance unit (3) at the top right. Connect the system connection hose (2) to the pneumatic system. Operating Instructions 868-M PREMIUM - 01.0 - 05/2017...

  • Page 138: Setting The Operating Pressure

    ± 0.5 bar. Fig. 79: Setting the operating pressure ① ② (1) - Pressure controller (2) - Pressure gage To set the operating pressure: Pull the pressure controller (1) up. Operating Instructions 868-M PREMIUM - 01.0 - 05/2017...

  • Page 139: Checking The Lubrication

    Check at the inspection glass (3) whether the warning indica- tor is lit red or the oil level has dropped below the minimum marking (1). If this is the case, top off oil ( p. 112). Operating Instructions 868-M PREMIUM - 01.0 - 05/2017...

  • Page 140: Performing A Test Run

    11. Transfer the desired quick function from the push button to the favorite button ( p. 52). 12. Start the sewing test at low speed. 13. Gradually increase the speed until the working speed is reached. Operating Instructions 868-M PREMIUM - 01.0 - 05/2017...

  • Page 141: Decommissioning

    Remove residual oil from the oil pan using a cloth. Cover the control panel to protect it from soiling. Cover the control to protect it from soiling. Cover the entire machine if possible to protect it from contam- ination and damage. Operating Instructions 868-M PREMIUM - 01.0 - 05/2017...
  • Page 142 Decommissioning Operating Instructions 868-M PREMIUM - 01.0 - 05/2017...

  • Page 143: Disposal

    When disposing of the machine, be aware that it consists of a range of different materials (steel, plastic, electronic components, etc.). Follow the national regulations when disposing these materials. Operating Instructions 868-M PREMIUM - 01.0 - 05/2017...
  • Page 144 Disposal Operating Instructions 868-M PREMIUM - 01.0 - 05/2017...

  • Page 145: Troubleshooting

    Email: service@duerkopp-adler.com Internet: www.duerkopp-adler.com 10.2 Messages of the software Should a fault occur, refer to the  Service Instructions or turn to Customer Service. Do not attempt to correct the error yourself. Operating Instructions 868-M PREMIUM - 01.0 - 05/2017...

  • Page 146: Errors In Sewing Process

    ( p. 43). Thread-guiding parts, such Check threading path as thread guides, are ( p. 26). sharp-edged Throat plate or hook have Have parts reworked by been damaged by the qualified specialists needle Operating Instructions 868-M PREMIUM - 01.0 - 05/2017...
  • Page 147 ( p. 26,  p. 40). thread have not been threaded correctly Needle Needle thickness is Use recommended needle breakage unsuitable for the sewing thickness ( p. 147). material or the thread Operating Instructions 868-M PREMIUM - 01.0 - 05/2017...
  • Page 148 Troubleshooting Operating Instructions 868-M PREMIUM - 01.0 - 05/2017...

  • Page 149: Technical Data

    Needle thread [Nm] 120/3 - 10/3 thickness Stitch length [mm] 12/12 Speed maximum 2500 2500 [min Speed set 2500 2500 [min at the factory Sewing foot stroke [mm] Lifting height [mm] Operating Instructions 868-M PREMIUM - 01.0 - 05/2017...
  • Page 150 • Material thickness detection with programmable functions (sewing speed, sewing foot pressure, sewing foot stroke and thread tension) • programmable sewing foot pressure via stepper motor (in combination with compression spring); depending on material thickness detection Operating Instructions 868-M PREMIUM - 01.0 - 05/2017...
  • Page 151 • integrated LED sewing lamp including power supply and dim- ming function • intuitive control software with graphical user interface • up to 999 different seam programs supporting a maximum of 30 individual seam sections each Operating Instructions 868-M PREMIUM - 01.0 - 05/2017...
  • Page 152 Technical data Operating Instructions 868-M PREMIUM - 01.0 - 05/2017...

  • Page 153: Appendix

    Appendix 12 Appendix Fig. 81: Tabletop drawing Operating Instructions 868-M PREMIUM - 01.0 - 05/2017...
  • Page 154 Appendix Fig. 82: Wiring diagram (1) Operating Instructions 868-M PREMIUM - 01.0 - 05/2017...
  • Page 155 Appendix Fig. 83: Wiring diagram (2) Operating Instructions 868-M PREMIUM - 01.0 - 05/2017...
  • Page 156 Appendix Fig. 84: Wiring diagram (3) Operating Instructions 868-M PREMIUM - 01.0 - 05/2017...
  • Page 157 Appendix Fig. 85: Wiring diagram (4) Operating Instructions 868-M PREMIUM - 01.0 - 05/2017...
  • Page 158 Appendix Fig. 86: Wiring diagram (5) Operating Instructions 868-M PREMIUM - 01.0 - 05/2017...
  • Page 159 Appendix Fig. 87: Wiring diagram (6) Operating Instructions 868-M PREMIUM - 01.0 - 05/2017...
  • Page 160 Appendix Fig. 88: Wiring diagram (7) Operating Instructions 868-M PREMIUM - 01.0 - 05/2017...
  • Page 162 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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