Duerkopp Adler 868 Service Instructions Manual
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Duerkopp Adler 868 Service Instructions Manual

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Postfach 17 03 51, D-33703 Bielefeld • Potsdamer Straße 190, D-33719 Bielefeld
Telefon +49 (0) 521 / 9 25-00
Ausgabe / Edition:
Änderungsindex
01/2009
Rev. index: 00.0
Spezialnähmaschine
•
Telefax +49 (0) 521 / 9 25 24 35 • www.duerkopp-adler.com
Printed in Federal Republic of Germany
868
Serviceanleitung

Service Instructions

Teile-Nr./Part.-No.:
0791 868641
D
GB

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  • Page 1: Service Instructions

    Spezialnähmaschine Serviceanleitung Service Instructions Postfach 17 03 51, D-33703 Bielefeld • Potsdamer Straße 190, D-33719 Bielefeld Telefon +49 (0) 521 / 9 25-00 • Telefax +49 (0) 521 / 9 25 24 35 • www.duerkopp-adler.com Ausgabe / Edition: Änderungsindex Teile-Nr./Part.-No.: 01/2009 Rev.
  • Page 2 Alle Rechte vorbehalten. Eigentum der Dürkopp Adler AG und urheberrechtlich geschützt. Jede, auch auszugsweise Wiederverwendung dieser Inhalte ist ohne vorheriges schriftliches Einverständnis der Dürkopp Adler AG verboten. All rights reserved. Property of Dürkopp Adler AG and copyrighted. Reproduction or publication of the content in any manner, even in extracts, without prior written permission of Dürkopp Adler AG, is prohibited.

  • Page 3: General Safety Instructions

    General safety instructions The non-observance of the following safety instructions can cause bodily injuries or damages to the machine. 1. The machine must only be commissioned in full knowledge of the instruction book and operated by persons with appropriate training. 2.

  • Page 5: Table Of Contents

    Contents Page: Service Instructions Class 868 (Edition 01/2009) General notes Gauges........... . . Description of the locking positions .
  • Page 6 Contents Page: Stitch length limitation ..........2.10 Stitch equality of the forward and backward stitch .

  • Page 7: General Notes

    General notes The present service instructions describes the adjustment of the special sewing machine 868. ATTENTION ! The operations described in the service instructions must only be executed by qualified staff or correspondingly instructed persons respectively! Caution: Risk of injury ! In case of repair, alteration or maintenance work turn off the main switch and disconnect the machine from the pneumatic supply system.
  • Page 8 Further gauges: Setting gauge 0868 290113 chapter 2.4 Needle bar linkage Setting gauge 0868 290153 chapter 2.5 Post bed feed Setting gauge 0868 290163 chapter 2.5 Post bed feed Setting gauge 0868 290184 chapter 2.3.3 Position of the advance shaft Setting gauge 0868 290020 chapter 2.4.2 Transmission lever Setting gauge 0868 290194...
  • Page 9 Notes:...

  • Page 10: Description Of The Locking Positions

    Description of the locking positions With the locking pin 1 and the arresting grooves 2 and 3 in the arm shaft crank 4 the sewing machine can be arrested in two adjusting positions. Position I = Locking pin Ø 5 mm for large groove = Looping stroke, needle bar height Position II = Locking pin Ø...

  • Page 11: Graduation On The Handwheel

    Graduation on the handwheel The handwheel 2 has degree marks printed on it. Certain settings are effectuated by using these handwheel positions. – Turn the handwheel until the degree mark mentioned in this manual points to the index 3. – Carry out the described adjustment.

  • Page 12: Sewing Machine

    Sewing machine Position of the arm shaft crank on the arm shaft Caution: Risk of injury ! Turn the main switch off ! Check and set the position of the arm shaft crank only when the machine is switched off. Standard checking The arm shaft crank 1 is fastened with the three screws 2 on the arm shaft 4.

  • Page 13: Upper And Lower Toothed Belt Wheel / Toothed Belt

    Upper and lower toothed belt wheel / toothed belt 2.2.1 Position of the upper toothed belt wheel Caution: Risk of injury ! Turn the main switch off ! Check and set the position of the upper toothed belt wheel only with the sewing machine switched off.

  • Page 14: Position Of The Lower Toothed Belt Wheel

    2.2.2 Position of the lower toothed belt wheel Caution: Risk of injury ! Turn the main switch off ! Check and set the position of the lower toothed belt wheel only with the sewing machine switched off. Standard checking The screws in the toothed belt wheel 2 have to sit on the flat spot 1 of the lower shaft 5.

  • Page 15: Bottom Feed And Stitch Regulator Gear

    Bottom feed and stitch regulator gear 2.3.1 Basic setting of stitch adjustment Caution: Risk of injury ! Turn the main switch off ! Set the basic setting of stitch adjustment only with the sewing machine switched off. Standard checking When the setting wheel 5 is set to the position “0", the stitch regulator gear should not have any clearance.
  • Page 16 Adjusting the eccentric The eccentric 3 has to be adjusted so that the open end 4 of the eccentric slot superposes with screw 2. Loosen screw 2. – Turn the eccentric 3 through the bore hole 1 so that the open end 4 –...

  • Page 17: Adjusting The 2Nd Stitch Length

    2.3.2 Adjusting the 2nd stitch length Caution: Risk of injury ! Turn the main switch off ! Set the basic stitch adjustment only with the sewing machine switched off. Set the upper setting wheel 1 to “0”. – Unscrew screw 2 and pull off the setting wheel 3. –...

  • Page 18: Position Of The Advance Shaft

    2.3.3 Position of the advance shaft Caution: Risk of injury ! Turn the main switch off ! Set and check the feed dog and the stitch adjustment gear only with the sewing machine switched off. – Unscrew the advance shaft. Loosen the screws on the adjustment rings 2 and 3.

  • Page 19: Feed Gear Basic Setting

    2.3.4 Feed gear basic setting 3 10 Caution: Risk of injury ! Turn the main switch off ! Set and check the feed dog and the stitch adjustment gear only with the sewing machine switched off. Unhook spring 1. – Loosen the clamping screw on the block 2.

  • Page 20: Needle Bar Linkage

    Needle bar linkage 2.4.1 Align the needle bar linkage laterally Caution: Risk of injury ! Turn the main switch off ! Check and set the needle bar linkage only with the sewing machine switched off. Loosen the screws on the adjustment rings 3 and 4. –...

  • Page 21: Transmission Lever

    2.4.2 Transmission lever Caution: Risk of injury ! Turn the main switch off ! Check and set the transmission lever only with the sewing machine switched off. The lever 3 transmits the movement of the advance shaft to the needle bar linkage.

  • Page 22: Thread Lever

    2.4.2 Thread lever Caution: Risk of injury ! Turn the main switch off ! Check and set the thread lever only with the sewing machine switched off. Loosen screw 1. – – Align the thread lever laterally so that the clearance of the traction rod 2 on the yoke is equal at the points 3 and 4.

  • Page 23: Post Bed Feed

    Post bed feed 2.5.1 Aligning the post bed feed Caution: Risk of injury ! Turn the main switch off ! Check and set the post bed feed only with the sewing machine switched off. – Set the upper stitch setting wheel (chapter 2.3.2) to “0“. Position the needle bar linkage by using the setting gauge 1 –...

  • Page 24: Feeding Motion Of The Feed Dog

    2.5.2 Feeding motion of the feed dog 180° Caution: Risk of injury ! Turn the main switch off ! Adjust the feeding motion of the feed dog only with the sewing machine switched off. Standard checking When the machine is set to position “180°” and the maximum stitch length is set, the movement of the feed dog should be the least possible.

  • Page 25: Lifting Motion Of The Feed Dog

    2.5.3 Lifting motion of the feed dog Caution: Risk of injury ! Turn the main switch off ! Adjust the lifting motion of the feed dog only with the sewing machine switched off. Standard checking The feed dog is supposed to have the same distance to the throat plate at its front and backward dead centre: –...

  • Page 26: Feed Dog Height

    2.5.4 Feed dog height Caution: Risk of injury ! Turn the main switch off ! Check and set the height of the feed dog only with the sewing machine switched off. Standard checking For a safe feed movement of the material the feed dog 2 should surpass the throat plate surface of 0.8 mm.

  • Page 27: Balance Weight

    2.5.5 Balance weight Caution: Risk of injury ! Turn the main switch off ! Check and set the balance weight only with the sewing machine switched off. Standard checking The balance weight 1 has to be positioned in a way, that a stuck in Allen key 3 stands parallel to the bed plate 2 when the handwheel is set to position “30°”.

  • Page 28: Needle Penetration In Feeding Direction

    2.5.6 Needle penetration in feeding direction Caution: Risk of injury ! Turn the main switch off ! Check and set the needle penetration only with the sewing machine switched off. Standard checking The needle 1 should penetrate the centre of the feed dog’s 2 stitch hole when the stitch length is set to “0”.

  • Page 29: Hook, Looping Stroke And Needle Bar Height

    Hook, looping stroke and needle bar height 2.6.1 Hook height Caution: Risk of injury ! Turn the main switch off ! Check and set the hook height only with the sewing machine switched off. The hook height is synchronized to the movement of the thread lever and very important for a satisfactory sewing result.
  • Page 30 Notes:...

  • Page 31: Looping Stroke

    2.6.2 Looping stroke Caution: Risk of injury ! Turn the main switch off ! Check and set the looping stroke only with the sewing machine switched off. Standard checking The looping stroke is the way of the needle bar from its bottom dead centre to the point where the hook tip 2 stands in the middle of the needle 1.

  • Page 32: Needle Bar Height

    2.6.3 Needle bar height Caution: Risk of injury ! Turn the main switch off ! Check and set the needle bar height only with the sewing machine switched off. Standard checking The needle bar’ s height is to be set in a way that in looping stroke position the hook tip stands in the bottom third of the needle scarf when the stitch length is set to “...

  • Page 33: Distance Between Hook And Needle

    2.6.4 Distance between hook and needle Caution: Risk of injury ! Turn the main switch off ! Check and set the hook distance only with the sewing machine switched off. Standard checking In looping stroke position the distance between the hook tip and the needle scarf should not be more than 0.1 mm.

  • Page 34: Needle Guard

    2.6.5 Needle guard Caution: Risk of injury ! Turn the main switch off ! Check and set the needle guard only with the sewing machine switched off. Standard checking The needle guard 2 is to prevent a contact of the needle with the hook tip.

  • Page 35: Bobbin Case Opening

    Bobbin case opening 2.7.1 General The thread lever has to pull the thread through in between the bobbin case and its holder. For the thread to slip through without any hindrance the bobbing case must be opened in this particular moment. That way the desired seam pattern can be achieved with the lowest possible thread tension.
  • Page 36 Correction – Pull the hook cover upward and open it. Turn the handwheel until the opening finger 1 has attained its – maximum opening movement. Loosen screw 2. – Adjust the opening finger 1 so that the lug of the bobbin case 3 is –...

  • Page 37: Timing Of Opening

    2.7.3 Timing of opening Caution: Risk of injury ! Turn the main switch off ! Check and set bobbin case opening only with the sewing machine switched off. Standard checking The sewing thread must be able to slip through the points 1 and 2 without any hindrance.

  • Page 38: Feeding Foot And Presser Foot

    Feeding foot and presser foot 2.8.1 Basic stroke gearing setting Caution: Risk of injury ! Turn the main switch off ! Check and set the basic stroke gearing setting only with the sewing machine switched off. Standard checking With the arm cover removed and the screw 1 unscrewed, the tongues 2 of the stroke gearing 3 have to stand parallel to each other.
  • Page 39 Notes:...

  • Page 40: Feeding Foot And Presser Foot Stroke

    2.8.2 Feeding foot and presser foot stroke Caution: Risk of injury ! Turn the main switch off ! Check and set the sewing feet stroke only with the sewing machine switched off. Standard checking The strokes of both sewing feet should be identical when the setting wheel 4 for the sewing foot stroke is set to “3".

  • Page 41: Stroke Motion Of The Feeding Foot

    2.8.3 Stroke motion of the feeding foot Caution: Risk of injury ! Turn the main switch off ! Check and set the stroke motion only with the sewing machine switched off. Prerequisite · The strokes of the feeding foot and the presser foot must be identical (see chapter 2.8.1) ·...

  • Page 42: Sewing Foot Pressure

    2.8.4 Sewing foot pressure Standard checking The material that is to be sewn must not “float”. It should not be exerted more pressure than necessary. Correction Set the sewing foot pressure by turning screw 1. – = Turn screw 1 clockwise. Increase the pressure = Turn screw 1 counter-clockwise.

  • Page 43: Stitch Length Limitation

    Stitch length limitation Depending on the sewing equipment used, the stitch length setting has to be limited to 6, 9 or 12 mm. Unscrew the screw 2 on the stitch length setting wheel. – Lift off the setting wheel 1. –...

  • Page 44: Stitch Equality Of The Forward And Backward Stitch

    2.10 Stitch equality of the forward and backward stitch Caution: Risk of injury ! Turn the main switch off ! Set the stitch equality only with the sewing machine switched off. Standard checking The stitch length of the forward and backward stitch should be identical.

  • Page 45: Sewing Foot Lifting

    2.11 Sewing foot lifting 2.11.1 Mechanical sewing foot lifting Caution: Risk of injury ! Turn the main switch off ! Check and set the clearance of the lifting mechanism only with the sewing machine switched off. Standard checking The lifting shaft 6 is supposed to run smoothly but should not have any end play.

  • Page 46: Height Of The Sewing Feet Arrested With Hand Lever

    2.11.2 Height of the sewing feet arrested with hand lever Caution: Risk of injury ! Turn the main switch off ! Check and set the sewing foot lifting only with the sewing machine switched off. Standard checking The sewing feet 4 can be arrested in lifted position with the hand lever 1.

  • Page 47: Height Of The Lifted Sewing Feet

    2.11.3 Height of the lifted sewing feet Caution: Risk of injury ! Turn the main switch off ! Check and set the height of the lifted sewing feet only with the sewing machine switched off. Standard checking The pneumatically or via knee lever lifted sewing feet 4 are supposed to have a distance of 20 mm to the throat plate when the needle bar is in its upper dead centre.

  • Page 48: Thread-Guiding Parts

    2.12 Thread-guiding parts 2.12.1 Thread regulator Caution: Risk of injury ! Turn the main switch off ! Check and set the thread regulator only with the sewing machine switched off. Standard checking The position of the thread regulator 1 depends on the thickness of the material to be sewn, the thread size and the chosen stitch length.

  • Page 49: Thread Take-Up Spring

    2.12.2 Thread take-up spring Caution: Risk of injury ! Turn the main switch off ! Check and set the thread take-up spring only with the sewing machine switched off. Standard checking The standard setting for the spring travel and spring tension only apply to usual thread sizes.

  • Page 50: Bobbin Winder

    2.13 Bobbin winder Caution: Risk of injury ! Turn the main switch off ! Check and set the bobbin winder only with the sewing machine switched off. Standard checking The bobbin winding operation must stop automatically when the bobbin is filled up to approx. 0.5 mm below the edge of the bobbin. The winder wheel must not have any end play but its moving should not be to sluggish either.
  • Page 51 Turn the winder bobbin so that the tear-off knife 12 points to the – fastening screw 1 on the right side. Loosen the screw on the engagement block 14. – – Set the winder flap so that between the thread on the bobbin and the winder flap remains a distance of 2 - 3 mm (insert a spacer).

  • Page 52: Thread Cutter

    2.14 Thread cutter 2.14.1 General 25 22 24 13...

  • Page 53: Thread-Pulling Knife Height

    Position of the thread-pulling knife The thread-pulling knife 1 cannot be shifted on the knife carrier 3. This allows to exchange the thread-pulling knife without having to reset the cutting pressure. Screws and levers The screws 11 and 12 are fixed opposite the flat spot on the shaft 23. In order to avoid any collision the lever 24 must be fitted with its short side onto the lever 13 .

  • Page 54: Thread-Pulling Knife

    2.14.3 Thread pulling knife Caution: Risk of injury ! Turn the main switch off ! Check and set the thread-pulling knife only with the sewing machine turned off. Standard checking In the thread-pulling knife’s 1 resting position the distance between the control cam 4 (highest point) and the roller 7 should be max.
  • Page 55 Correction Loosen the screws (4x) on the circlip 5 and push it towards the – hook bearing. Tighten the screws (4x) on the circlip 5 again in order to preserve the looping stroke’s position unaltered. Loosen the screws (2x) on the control cam 4. –...

  • Page 56: Swing Range Of The Thread-Pulling Knife

    2.14.4 Swing range of the thread-pulling knife Caution: Risk of injury ! Turn the main switch off ! Check and set the swing range of the thread-pulling knife only with the sewing machine turned off. Standard checking The thread-pulling knife 1 must be able to exercise from its parking position the maximum swing angle without colliding with the hook cover.

  • Page 57: Counter-Knife And Lower Thread Clamp

    2.14.5 Counter-knife and lower thread clamp 20 17 Caution: Risk of injury ! Turn the main switch off ! Check and set the counter-knife and lower thread clamp only with the sewing machine turned off. Standard checking The thread is to be trimmed safely with as little pressure as possible. A low trimming pressure keeps the knife wear low! If the trimming pressure is too high, this can lead to the counter-knife’s breaking!
  • Page 58 Correction cutting pressure Turn the handwheel until the thread-pulling knife 1 can be swung – out. Swing out the thread-pulling knife 1 until a distance of about 2 mm – occurs between the two blades (see diagram). Loosen screw 17 and turn the counter-knife carrier 18 on the screw –...

  • Page 59: Trimming Position

    2.14.6 Trimming position Caution: Risk of injury ! Turn the main switch off ! Check and set the trimming position only with the sewing machine switched off. Standard checking With the factory setting the trimming position is the position “thread lever in its upper dead centre”...

  • Page 60: Potentiometer In The Arm

    2.15 Potentiometer in the arm Sewing machines with thread trimmer are equipped with a potentiometer in order to limit the driving speed of higher sewing foot strokes. Through this potentiometer the control recognizes the sewing foot stroke and limits the driving speed. 2.15.1 Basic setting without control panel Set sewing machines without control panel according to the following...

  • Page 61: Basic Setting Without Control Panel

    2.15.2 Basic setting with the control panel V810 or V820 Caution: Risk of injury ! The adjustment of the potentiometer is done with the main switch switched on. Work with utmost caution. Loosen the stop screw 1 for the potentiometer 2. –...

  • Page 62: Check The Potentiometer Adjustment

    2.15.3 Check the potentiometer adjustment – Keep the key “P” pressed and switch on the main switch. – Enter the technician level. – Select the parameter “F-188”. – Actuate the key “E”. The current Speedomat grade and the corresponding driving speed limitation are displayed.

  • Page 63: Connections Pcb

    2.16 Connections PCB For the sake of completeness, the various connections of the PCB below are explained here. X11 Control Sewing Drive X12 Solenoid Thread Tension X13 Solenoid Additional Thread Tension X14 Solenoid X15 Solenoid Sewing Foot X16 Solenoid Tack Stroke Adjustment Pneum.

  • Page 64: Oil Lubrication

    Oil lubrication Caution: Risk of injury ! Oil can cause skin eruption. Avoid a longer contact with the skin. Wash yourself thoroughly after a contact. ATTENTION ! The handling and disposal of mineral oils is subject to legal regulations. Deliver used oil to an authorized collecting station. Protect your environment.

  • Page 65: Hook Lubrication

    Hook lubrication Caution: Risk of injury ! Turn the main switch off ! Adjust the hook lubrication only with the sewing machine switched off. Make a functional test only with utmost caution when the sewing machine is running. Standard checking The necessary oil quantity for the correct lubrication of the hook has been adjusted by the manufacturer.

  • Page 66: Maintenance

    Maintenance Caution: Risk of injury ! Turn the main switch off ! The maintenance of the sewing machine must only be done when the machine is switched off. The daily or weekly maintenance work (cleaning and oiling) to be carried out by the operators of the sewing machine is described in the operating instructions (part 1).

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