868 Special Sewing Machine Instruction manual 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: 03/2011 Änderungsindex Rev. index: 00.0 Printed in Federal Republic of Germany Teile-Nr./Part.-No.
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.
Foreword This instruction manual is intended to help the user to become familiar with the machine and take advantage of its application possibilities in accordance with the recommendations. The instruction manual contains important information on how to operate the machine securely, properly and economically. Observation of the instructions eliminates danger, reduces costs for repair and down-times, and increases the reliability and life of the machine.
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. Before putting into service also read the safety rules and instructions of the motor supplier. 3. The machine must be used only for the purpose intended. Use of the machine without the safety devices is not permitted.
Contents Page: Preface and general safety instructions Part 1: Operating Instructions Class 868 – Original Instructions (Edition 03/2011) 1 Product description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 2 Designated use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 3 Subclasses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 4 Optional equipment.
Contents Page: 9 9.1 9.2 Maintenance Cleaning and testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 37 10 10.1 10.2 Optional equipment Seam center guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1 Product description The DÜRKOPP ADLER 868 is a special sewing machine for universal use. · · · · · · · 2 It is a flatbed double-lockstitch machine with bottom feed, needle feed and alternating upper foot feed. Depending on the subclass it comes as single or double needle automat, with or without electromagnetic thread cutter, with or without edge trimmer. Equipped with a large or oversized two-piece vertical hook. With a maximum of 20 mm fabric clearance when sewing feet are lifted.
This special sewing machine may be set up and operated only in dry, well-maintained premises. If the sewing machine is used in premises which are not dry and well-maintained it may be necessary to take further precautions, which should be agreed upon in advance (see EN 60204-31:1999).
868-390322 Double-needle double-lockstitch post bed machine with bottom feed, needle feed, alternating upper foot feed, electro-pneumatic rapid stroke adjustment with automatic speed limitation, operated via knee lever, electro-magnetic thread cutter, electro-pneumatic seam bartacking, electro-pneumatic second stitch length and sewing foot lifting. With large hook, with integrated sewing lamp. Left post.
4 Optional equipments For the 868 the following optional equipments are available: Optional equipment Subclasses 0867 590014 Electro-pneumatic needle cooler from the top 0867 590064 Pneumatic connection x x x x x 9780 000108 WE-8 maintenance unit for pneumatic optional equipments x x o o o 9822 510003 Halogen sewing lamp x x x x x 9880 867100 Sewing lamp add-on kit x x x x x 0798 500088 Sewing lamp transformer x x x x x 9880 867103 Sewing lamp LED x x x x x 9880 867102 Integrated sew
Please contact our Application Center (APC) for further optional equipment. E-Mail: marketing@duerkopp-adler.
5 Technical data Noise: Workplace-related emission value in accordance with DIN 45635-48-A-1-KL2 868-190020 LC = _dB (A) Stitch length: _ Material: LC = _dB (A) Stitch length: _ Material: LC = 78 dB (A) Stitch length: 6 Material: LC = 76 dB (A) Stitch length: 6 Material: LC = _dB (A) Stitch length: _ Material: 868-290020 868-190322 868-190322 868-390322 10 mm Sewing foot stroke: mm Speed: ____ min -1 mm Sewing foot stroke: mm Speed: ____ min -1 mm Sewing foot stroke: 1.
868-290322 868-390322 large large 1 2 1 2 Type of stitch 868-290020 large 868-190322 large 868-190020 Technical data subclasses large 5.1 Lockstitch 301 Hook type Number of needles Needle system 1 134-35 Needle size (depending on E-No.) [Nm] 170 Max. thread thickness [Nm] Stitch length - Forward - Backward [mm] 10 / 3 12 12 Number adj. stitch lengths 1 2 1 2 2 Max.
Threading scheme single-needle machine 11 1 2 10 3 9 4 8 5 7 6 0868 190xxx 0868 390xxx Threading scheme double-needle machine - 22 12 13 21 14 15 20 16 19 18 17 12
6 6.1 Operation Threading the needle thread Caution: danger of injury ! Turn off the main switch. The needle thread may only be threaded with the sewing machine switched off. – – – – – – – – Put the thread reel on the thread stand and lead the needle thread through the unwinder arm. The unwinder arm must be in vertical position above the thread reels. Thread in the thread through threading guide 1 and 2. Conduct the thread clockwise around the pre-tensioner wheel 3.
3 14 2 1 5 4 Fig. A: Correct thread interlacing in the center of the material Fig. B: Needle-thread tension too low or hook-thread tension too high Fig.
6.2 Adjusting the needle-thread tension Pre-tensioner When the main tensioner 2 and supplementary tensioner 3 are open (e.g. when the sewing feet are raised) the needle thread must be under slight residual tension. This residual tension is produced by the pre-tensioner 1. The pre-tensioner 1 simultaneously affects the length of the end of the severed needle thread (the starting thread for the next seam). – Basic setting: Turn knurled nut 4 until its front is flush with the bolt 5.
6.2.1 Function of the thread main tension and the thread supplementary tension in relation to the sewing foot lifting Only Efka DC 1550 DA 321G The thread supplementary tension can, at any time, be switched on or off by actuating the switch key 1 (see chapter 6.17) on the key block of the machine. To this end, the parameter F-255 must be set on “7". Parameter Sewing foot lifting Sewing foot lifting withing a seam after thread trimming Thread main tension Thread supplement.
6.2.3 Function of the thread’s supplementary tension in relation to the stroke adjustment and the Speedomat Only Efka DC 1550 DA 321G The thread’s supplementary tension can, at any time, be switched on and off by actuating the key 1 (see chapter 6.17) of the machine’s keypad. To that end, the parameter F-255 must be set to “7". Parameter Setting F-197 F-197 F-197 F-197 = = = = stroke adjustment max.
6.4 Short stitch The short stitch can be set mechanically forward as well as backward. The short stitch is set by turning the stop screw 2 with an Allen wrench (size 3): Clockwise à forward. Counterclockwise à backward. 6.4.1 Short stitch at the seam beginning When sewing without initial bartack the reliability of the seam beginning can be increased by beginning the seam with a short stitch.
6.5 Switching the supplementary tension on and off with machines without thread trimmer 1 2 The supplementary tension is being switched on and off with lever 1. Switching on – Push the handle 2 of lever 1 to the left. Switching off – Push the handle 2 of the lever 1 to the right.
6.6 Adjusting the thread regulator 3 2 1 Caution: danger of injury ! Turn off the main switch. The thread regulator may only be adjusted with the sewing machine switched off. The thread regulator 1 controls the quantity of needle thread required for stitch formation. The thread regulator must be precisely adjusted for an optimum result. At the correct setting the needle-thread loop must slide at low tension over the thickest point of the hook. – Undo screw 2. – Adjust the thread regulator 1.
6.7 Winding on the hook thread 5 4 3 2 – – – – – – – – 1 2 6 Put the thread reel on the thread stand and conduct the needle thread through the unwinder arm. Conduct the thread through the thread guide 5, around the tensioner 4 and through the thread guide 3. Place the thread behind the blade 6 and sever it (in the arrow direction). Fit the bobbin 1 onto the bobbin winder. There is no need to wind the thread onto the bobbin by hand. Press the bobbin-winder lever 2 into the bobbin.
6.8 Changing the hook-thread bobbin 1 7 6 5 4 3 2 Caution: danger of injury ! Turn off the main switch. The hook-thread bobbin may only be changed with the machine switched off. Removing the empty bobbin – Raise the sewing foot. – Pull the hook cover 1 upwards and open it. – Lift the flap 5 and remove the empty bobbin 2. Inserting a full bobbin – Insert the full bobbin 2 so that it moves in the opposite direction of the hook when unwinding.
6.9 Setting the hook thread tension 1 2 Caution: danger of injury ! Turn off the main switch. The hook-thread tension may only be adjusted with the machine switched off. Setting the tension spring 2 – Set the tension spring 2 by turning the adjustment screw 1.
6.10 Inserting and changing the needle with single-needle machines 1 2 3 2 1 Caution: danger of injury ! Turn off the main switch. The needle may only be changed with the sewing machine switched off. – Turn the hand wheel, until the needle bar 1 has reached its highest position. – Loosen screw 2. – Pull the needle downwards out of the needle bar 1. – Push in the new needle into the hole of the needle bar 1 as far as it will go. Attention! The needle scarf 3 must point towards the hook.
6.11 Inserting and changing the needle with double-needle machines 1 2 3 4 Caution: danger of injury ! Turn off the main switch. The needle may only be changed with the sewing machine switched off. – Turn the hand wheel until the needle bar 1 has reached its highest position. – Loosen screw 3. – Pull the needle downwards out of the needle holder 2. – Push the new needle into the hole of the needle holder 2 as far as it will go.
6.12 Lifting the sewing foot 2 1 Subclasses 868-190020, 868-290020 The sewing feet can be lifted mechanically by actuating the knee lever 1. Subclasses 868-190322, 868-290322, 868-390322 The sewing feet can be lifted electro-pneumatically by actuating the pedal 2 or the knee lever 1. Raising the sewing foot mechanically (knee lever) – To adjust the position of the material (e.g. for corrective purposes), push the knee lever 1 to the right.
6.13 Locking the sewing feet in lifted position 1 1 – Push the lever 1 downwards. The sewing feet are locked in lifted position. – Push the lever 1 upward. The sewing feet’s position is unlocked. 2 Or – Lift the sewing feet pneumatically by pushing the knee switch. The lever 1 then moves back into its initial position. 6.14 Sewing-foot pressure The required sewing-foot pressure is set with the setting wheel 2. CAUTION ! The material must not ”swim”. Do not set a higher pressure than is necessary.
6.15 Sewing-foot stroke 2 1 3 The special sewing machine 868 has, depending on the subclass, as standard equipment two setting wheels for the sewing foot stroke. With the left setting wheel 2 the standard sewing foot stroke from 1 to 9 mm is selected. With the right setting wheel 1 an increased sewing foot stroke from 1 to 9 mm is selected.
Operation mode of the quick stroke adjustment The activation period of the maximum sewing foot stroke depends on the set operation mode. It is possible to choose between three operation modes. The individual operation modes are determined by the adjustment of the parameters F-138 and F-184 at the control panel (see enclosed instructions of the motor manufacturer).
6.16 Setting the stitch length 3 2 1 The special sewing machines 868 are, depending on the subclass, equipped with two setting wheels. Thus, two different stitch lengths can be sewn, that are activated by actuating a key (see chapter 6.17). The two stitch lengths are set with the setting wheels 1 and 2 on the machine arm. – Set the higher stitch length with the upper setting wheel 1. Setting 1 = min. stitch length Setting 12 = max.
6.17 Key pad on the machine arm 10 9 8 Key 7 6 5 4 3 2 1 Function 1 Supplementary thread tension If the key is lit up: Supplementary thread tension is switched on. If the key is not lit up: Supplementary thread tension is switched off. 2 2 stitch length If the key is lit up: Higher stitch length (upper setting wheel) is active If the key is not lit up: Smaller stitch length (lower setting wheel) is active 3 Recalling or suppressing the initial or final bartack.
LED Function 7 and 8 Display for empty bobbin with residual thread monitor (left/ right bobbin) 10 LED display “power on" The function of key 9 can be selected with the screw 6 underneath the key 5. – Select a function. Example: 5 = Manually sewing backward. – Turn in the screw 6 underneath the key 5 and turn it 90° to the right (the slot stands vertically). The function can now be called via both keys 5 and 9.
8 Sewing This description is based on the following assumptions: – The machine is a single-needle machine equipped with a: - thread trimmer - electro-pneumatic seam bartacking and sewing foot lifting - electro-pneumatic rapid stroke adjustment – The following functions are set at the operating panel: Initial bartack: ON Final bartack: ON Position of the sewing foot before and after the cutting DOWN Needle position before the cutting: – – DOWN (Position 1) Needle position after the cutting: UP Main
6 Sewing an intermediate bartack 5 4 3 - Push down the stitch regulator lever 6. The machine sews reverse stitches as long as the stitch regulator lever is pressed down. The rotation speed is determined through the pedal. or - Actuate key 5. Sewing over a cross seam. (max. sewing foot stroke) The max. sewing foot stroke is switched on. The rotation speed is limited to 1600 min . Operation modes of the max. sewing foot stroke: - 1 - Press briefly the knee switch to switch on the max.
9 9.1 Maintenance Cleaning and testing Caution: danger of injury ! Turn off the main switch. Maintenance may only be carried out with the machine switched off! Maintenance work must be carried out no less frequently than at the intervals given in the tables (see ”operating hours” column). Maintenance intervals may need to be shorter when processing heavy-shedding materials. A clean machine is a trouble-free machine.
6 4 8 2 10 3 1 4 2 Maintenance work to be carried out 5 Explanation Operating hours Sewing drive Clean fan grille 2. (e.g. with an air blow gun) Remove lint and pieces of thread from air-intake openings. 8 Check condition and tension of V-belt 1. It must be possible to depress the V-belt by about 10 mm by pressing it with a finger at its mid-point. 160 Check water level in pressure regulator. The water level must not rise to the level of the filter cartridge 3.
9.2 Lubrication 1 2 3 Caution: danger of injury ! Oil can cause skin eruptions. Avoid protracted contact with the skin. In the event of contact, thoroughly wash the affected area. CAUTION: The handling and disposal of mineral oils is subject to legal regulation. Deliver used oil to an authorised collection point. Protect your environment. Take care not to spill oil.
10 Optional equipment 10.1 Seam center guide General information The seam center guide serves as guiding aid when topstitching. It is used for guiding the center of two seams with equal distance so that the distance to the left and to the right needle is equal. Attention! The pressure for the seam center guide must not exceed 3 bar. Check the pressure at the manometer 1 and set it using the turning handle 2.
10.2 Repair When the machine is damaged or parts are worn please contact: DÜRKOPP ADLER AG Potsdamer Str. 190 D-33719 Bielefeld Phone: +49 (0) 180 5 383 756 Fax: +49 (0) 521 925 2594 E-mail: service@duerkopp-adler.com Internet: www.duerkopp-adler.
