867 Operating Manual All rights reserved. Property of Dürkopp Adler AG and protected by copyright. Any reuse of these contents, including extracts, is prohibited without the written approval in advance of Dürkopp Adler AG. Copyright © Dürkopp Adler AG - 2012 Contents 1 About this manual.................................................................................5 1.1 Scope of application of the manual..........................................................5 1.2 Applicable documentation........................................................................5 1.3 Damage during transport.........................................................................5 1.4 Limitation of liability..................................................................................5 1.5 Symbols used..........................................................................................6 1.6 Figures.....................................................................................................6 2 Safety instructions................................................................................7 2.1 General safety instructions......................................................................7 2.2 Signal words and symbols used in safety instructions.............................9 3 Performance description....................................................................11 3.1 Features.................................................................................................11 3.2 Declaration of conformity.......................................................................12 3.3 Intended use..........................................................................................12 3.4 Technical data.......................................................................................12 3.4.1 Noise emission......................................................................................12 3.4.2 Data overview by submodel...................................................................13 3.4.3 Additional equipment and manuals........................................................19 4 Device description...............................................................................21 5 Operating instructions........................................................................23 5.1 Switching the power supply on and off..................................................23 5.2 Inserting and replacing the needle.........................................................24 5.2.1 Needle change on 1-needle machines..................................................25 5.2.2 Needle change on 2-needle machines..................................................26 5.2.3 Changing needles on switchable needle bars.......................................27 5.3 Threading in the needle thread..............................................................28 5.3.1 Needle thread threading on 1-needle machines....................................29 5.3.2 Needle thread threading on 2-needle machines....................................31 5.3.3 Needle thread threading on machines with a clean seam start.............32 5.4 Inserting and winding on the hook thread..............................................33 5.5 Replacing the hook thread bobbin.........................................................36 5.6 Thread tension.......................................................................................37 5.6.1 Adjusting the needle thread tension......................................................38 5.6.2 Removing blocking of the needle thread tension...................................41 5.6.3 Opening the needle thread tensioner....................................................41 5.6.4 Adjusting the hook thread tension.........................................................42 5.7 Setting the thread regulator...................................................................43 5.8 Venting the sewing foot.........................................................................44 5.8.1 Mechanical lifting with the knee lever....................................................44 5.8.2 Electro-pneumatic lifting with a foot pedal.............................................44 5.9 Locking the sewing feet in the upper position........................................45 5.10 Setting the sewing foot pressure...........................................................46 Operating manual 867 Version 01.0 - 12/2012 1 Contents 5.10.1 Removing blocking of the adjusting wheel............................................47 5.11 Setting the sewing foot stroke...............................................................48 5.11.1 Limiting of number of stitches with an increased sewing foot stroke.....48 5.11.2 Setting the stroke height........................................................................49 5.11.3 Quick stroke adjustment via knee switch..............................................50 5.11.4 Removing blocking of the sewing foot pressure adjustment wheel.......51 5.12 Stitch length...........................................................................................52 5.12.1 Adjusting the stitch length.....................................................................52 5.12.2 Sewing with 2 stitch lengths..................................................................53 5.12.3 Removing blocking of the adjusting wheel............................................54 5.12.4 Sewing backwards................................................................................55 5.13 Quick functions on the keypad..............................................................56 5.13.1 Activating function keys.........................................................................56 5.13.2 Transferring a key function to the additional switch..............................58 5.14 Switching the binder..............................................................................59 5.15 Switching switchable needle bars.........................................................60 5.16 Operating the controller.........................................................................61 5.17 Sewing...................................................................................................62 6 Maintenance.........................................................................................65 6.1 Cleaning work........................................................................................65 6.1.1 Cleaning the machine............................................................................65 6.1.2 Cleaning the motor fan sieve.................................................................67 6.2 Checking the oil level............................................................................68 6.3 Checking the pneumatic system...........................................................71 6.4 Repairs..................................................................................................73 7 Set-up instructions..............................................................................75 7.1 Checking the scope of delivery.............................................................75 7.2 Removing the transport securing devices.............................................76 7.3 Fitting the frame components................................................................77 7.4 Completing the table plate.....................................................................78 7.4.1 Completing a short arm table plate.......................................................78 7.4.2 Completing a long arm table plate.........................................................79 7.5 Fastening the table plate to the frame...................................................80 7.6 Setting the working height.....................................................................81 7.7 Controller...............................................................................................82 7.7.1 Fitting the control...................................................................................83 7.7.2 Fit the pedal and setpoint device...........................................................84 7.8 Inserting the machine upper section.....................................................85 7.9 Fitting the oil extraction line...................................................................86 7.10 Fitting the knee lever.............................................................................87 7.10.1 Fitting the mechanical knee lever..........................................................87 7.10.2 Fitting the electric knee lever.................................................................88 7.11 Fitting the control panel.........................................................................89 2 Operating manual 867 Version 01.0 - 12/2012 Contents 7.12 Electrical connection..............................................................................90 7.12.1 Checking the mains voltage...................................................................90 7.12.2 Fitting and connecting the sewing lamp and sewing lamp transformer.90 7.12.3 Establishing equipotential bonding........................................................94 7.12.4 Connecting the controller.......................................................................95 7.12.5 Connecting the sewing machine upper section.....................................96 7.12.6 Fitting and connecting the Hall sensor...................................................96 7.12.7 Connecting the electrical knee switch....................................................99 7.12.8 Fitting the M-Control circuit board........................................................100 7.12.9 Setting machine-specific parameters...................................................102 7.13 Pneumatic connection.........................................................................103 7.13.1 Fitting the maintenance unit.................................................................103 7.13.2 Setting the operating pressure.............................................................104 7.13.3 Pneumatic foot lifting...........................................................................104 7.14 Lubrication...........................................................................................105 7.15 Sewing text..........................................................................................107 8 Disposal..............................................................................................109 9 Appendix............................................................................................111 9.1 Table plate drawings............................................................................111 9.2 Table of maximum speeds...................................................................114 Operating manual 867 Version 01.0 - 12/2012 3 Contents 4 Operating manual 867 Version 01.0 - 12/2012 About this manual 1 About this manual 1.1 Scope of application of the manual This operating manual describes the set-up and intended use of the special sewing machine 867. It applies to all submodels listed in Section  3.4 Technical data. 1.2 Applicable documentation The device contains built-in components of other manufacturers, e.g. drive motors. The corresponding manufacturers have per- formed a hazard assessment for these purchased parts and con- firmed compliance of the design with the European and national specifications. The intended use of the built-in components is described in the corresponding manuals of the manufacturers. 1.3 Damage during transport Dürkopp Adler cannot be held liable for any damage during trans- port. Check the delivered product immediately after receiving it. Report any damage to the last transport manager. This also applies if the packaging is not damaged. Keep the machines, devices and packaging material in the con- dition they were at the time when the damage was identified. That secures any claims towards the transport company. Report all other complaints to Dürkopp Adler immediately after receiving the product. 1.4 Limitation of liability All information and notes in this operating manual have been compiled in accordance with the latest technology and the appli- cable standards and regulations. The manufacturer accepts no liability for any damage due to: • Failure to observe the instructions in the manual • Improper use • Unauthorized modifications to the machine • The deployment of untrained personnel • Damage during transport • Using spare parts not approved Operating manual 867 Version 01.0 - 12/2012 5 About this manual 1.5 Symbols used Correct setting Specifies the correct setting. Faults Specifies the faults that can occur due to an incorrect setting. Steps to be performed when operating the machine (sewing and equipping) Steps to be performed for servicing, maintenance and installation Steps to be performed via the software control panel The individual steps are numbered: 1. 1. First step 2. 2. Second step ... The sequence of the steps must always be followed.  Result of performing an operation Change to the machine or on the display Important Special attention must be paid to this point when performing a step. Information Additional information, e. g. on alternative operating possibilities. Sequence Specifies the work to be performed before or after a setting. Reference  A reference is provided to another place in the text. 1.6 Figures Depending on the submodel, the appearance of the machine varies in the following items: Length of the machine arms, number of adjusting wheels, position of the stitch adjustment lever, presence of the keypad, etc. When this makes no difference to the handling steps, the figures show only one machine version as an example. 6 Operating manual 867 Version 01.0 - 12/2012 Safety instructions 2 Safety instructions This section contains basic instructions for your safety. Read the instructions carefully before setting up, programming, maintaining or operating the machine. Make sure to follow the information included in the safety instructions. Failure to do this can result in serious injury and damage to the machine. 2.1 General safety instructions Only authorized persons may use the machine. Every person who works with the machine must have read the operating manual first. The machine may only be used as described in this manual. The operating manual must be available at the machine's location at all times. Also observe the safety instructions and the operating manual of the drive motor's manufacturer. Observe the generally applicable safety and accident prevention regulations and the legal regulations concerning industrial safety and the protection of the environment. All warnings on the machine must always be in legible condition and may not be removed. Missing or damaged labels must be replaced immediately. For the following work, the machine must be disconnected from the power supply using the main switch or by disconnecting the power plug: • Threading • Replacing the needle or other sewing tools • Leaving the workplace • Performing maintenance work and repairs Operating manual 867 Version 01.0 - 12/2012 7 Safety instructions Inspect the machine while in use for any externally visible damage. Interrupt your work if you notice any changes to the machine. Report any changes to your supervisor. A damaged machine may not be used any more. Machines or machine parts that have reached the end of their service life must not continue to be used. They must be disposed of according to the applicable legal require- ments. The machine may only be set up by qualified specialists. Maintenance work and repairs may only be carried out by qualified specialists. Safety equipment may not be removed or put out of service. If this cannot be avoided for a repair operation, the safety equipment must be refitted and put back into service immediately afterwards. Work on electrical equipment may only be carried out by qualified electrical specialists. The connecting cable must have a power plug approved in the specific country. The power plug may only be connected to the power cable by a qualified electrical specialist. Work on live components and equipment is prohibited. Exceptions are defined in DIN VDE 0105. Missing or faulty spare parts could impair safety and damage the machine. Therefore only use original spare parts from the manu- facturer. 8 Operating manual 867 Version 01.0 - 12/2012