Duerkopp Adler 868 Operating Instruction

868

Spezialnähmaschine

Betriebsanleitung

Instruction manual

D

GB

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.:

05/2008 Rev. index: 00.0 Printed in Federal Republic of Germany 0791 868740

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.

Copyright ©

Dürkopp Adler AG - 2008

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.

The instruction manual is intended to complement existing national
accident prevention and environment protection regulations.

The instruction manual must always be available at the machine/sewing
unit.

The instruction manual must be read and applied by any person that is
authorized to work on the machine/sewing unit. This means:

– Operation, including equipping, troubleshooting during the work

cycle, removing of fabric waste,

– Service (maintenance, inspection, repair) and/or
– Transport.

The user also has to assure that only authorized personnel work on the
machine.

The user is obliged to check the machine at least once per shift for
apparent damages and to immediatly report any changes (including the
performance in service), which impair the safety.

The user company must ensure that the machine is only operated in
perfect working order.

Never remove or disable any safety devices.

If safety devices need to be removed for equipping, repairing or
maintaining, the safety devices must be remounted directly after
completion of the maintenance and repair work.

Unauthorized modification of the machine rules out liability of the
manufacturer for damage resulting from this.

Observe all safety and danger recommendations on the machine/unit!
The yellow-and-black striped surfaces designate permanend danger
areas, eg danger of squashing, cutting, shearing or collision.

Besides the recommendations in this instruction manual also observe
the general safety and accident prevention regulations!

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

2. Before putting into service also read the safety rules and

3. The machine must be used only for the purpose intended. Use of

4. When gauge parts are exchanged (e.g. needle, presser foot, needle

5. Daily servicing work must be carried out only by appropriately

instruction book and operated by persons with appropriate training.

instructions of the motor supplier.

the machine without the safety devices is not permitted. Observe all
the relevant safety regulations.

plate, feed dog and bobbin) when threading, when the workplace is
left, and during service work, the machine must be disconnected
from the mains by switching off the master switch or disconnecting
the mains plug.

trained persons.

6. Repairs, conversion and special maintenance work must only be
carried out by technicians or persons with appropriate training.

7. For service or repair work on pneumatic systems, disconnect the
machine from the compressed air supply system (max. 7-10 bar).
Before disconnecting, reduce the pressure of the maintenance unit.
Exceptions to this are only adjustments and functions checks made
by appropriately trained technicians.

8. Work on the electrical equipment must be carried out only by
electricians or appropriately trained persons.

9. Work on parts and systems under electric current is not permitted,
except as specified in regulations DIN VDE 0105.

10. Conversion or changes to the machine must be authorized by us

and made only in adherence to all safety regulations.

11. For repairs, only replacement parts approved by us must be used.

12. Commissioning of the sewing head is prohibited until such time as

the entire sewing unit is found to comply with EC directives.

13. The line cord should be equipped with a country-specific mains

plug. This work must be carried out by appropriately trained
technicians (see paragraph 8).

It is absolutely necessary to respect the safety

instructions marked by these signs.

Danger of bodily injuries !

Please note also the general safety instructions.

Contents Page:

Preface and general safety instructions

Part 1: Operating Instructions Class 868

(Edition 05/2008)

1. Product description ............................................ 5

2. Designated use ............................................... 5

3. Subclasses .................................................. 6

4. Optional equipment............................................. 8

5. Technical data ................................................ 10

5.1 Technicaldatasubclasses ......................................... 11

6. Operation

6.1 Threading the needle thread ........................................ 13

6.2 Adjusting the needle-thread tension ................................... 15

6.2.1 Function of the thread main tension and the thread supplementary tension in relation

tothesewingfootlifting........................................... 16

6.2.2 Reparationseamwiththreadtensionalwaysclosed.......................... 16

6.2.3 Function of the thread’s supplementary tension in relation to the stroke adjustment

and the Speedomat.............................................. 17

6.3 Opening the thread tension ......................................... 17

6.4 Shortstitch .................................................. 18

6.4.1 Short stitch at the seam beginning .................................... 18

6.4.2 Shortstitchattheendofaseam ..................................... 18

6.4.3 Short stitch at the seam beginning and seam end ........................... 18

6.5 Switching the supplementary tension on and off with machines without thread trimmer ..... 19

6.6 Adjusting the thread regulator ....................................... 20

6.7 Winding on the hook thread......................................... 21

6.8 Changing the hook-thread bobbin ..................................... 22

6.9 Setting the hook thread tension ...................................... 23

6.10 Inserting and changing the needle with single-needle machines .................. 24

6.11 Inserting and changing the needle with double-needle machines .................. 25

6.12 Liftingthesewingfoot............................................ 26

6.13 Lockingthesewingfeetinliftedposition................................. 27

6.14 Sewing-footpressure ............................................ 27

6.15 Sewing-footstroke.............................................. 28

6.16 Setting the stitch length ........................................... 30

6.17 Keypadonthemachinearm........................................ 31

GB

7. Sewing drive and operating panel ................................... 32

8. Sewing ..................................................... 33

Contents Page:

9. Maintenance

9.1 Cleaning and testing ............................................. 35

9.2 Lubrication ................................................... 37

10. Optional equipment

10.1 Seamcenterguide.............................................. 38

1. Product description

The DÜRKOPP ADLER 868 is a special sewing machine for universal
use.

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.

A safety clutch prevents a changing of the hook setting or a hook

·

damage in the case of a thread deflection into the shuttle track.

Automatic wick lubricating with an inspection glass on the arm for

·

machine and hook lubrication.

Integrated winder.

·

2. Designated use

GB

The 868 class is a sewing machine designed for sewing light to
medium-heavy material. Such material is generally made of textile
fibers, but it may also be leather. It is used in the clothing industry and
for domestic and motor-vehicle upholstery.

This special sewing machine can also be used to produce so-called
technical seams. In this case, however, the operator must assess the
possible dangers which may arise (with which DÜRKOPP ADLER AG
would be happy to assist), since such applications are on the one hand
relatively unusual and, on the other, so varied that no single set of
criteria can cover them all. The outcome of this assessment may
require appropriate safety measures to be taken.

Generally only dry material may be sewn with this machine. The
material may be no thicker than 10 mm when compressed by the
lowered sewing feet. The material may not contain any hard objects,
since if it does the machine may not be operated without an
eye-protection device. No such device is currently available.

The seam is generally produced with textile-fibre sewing thread of
gauge up to 11/3 NeB (cotton), 11/3 Nm (synthetic) or 11/4 Nm
(covering yarn).
Before using any other thread the possible dangers arising must be
assessed and appropriate safety measures taken if necessary.

5

3. Subclasses

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).

As manufacturers of industrial sewing machines we proceed on the
assumption that personnel who work on our products will have
received training at least sufficient to acquaint them with all normal
operations and with any hazards which these may involve.

868-190020 Single-needle double-lockstitch post bed machine

with bottom feed, needle feed, alternating upper foot
feed and large hook.

867-290020 Double-needle double-lockstitch post bed machine

with bottom feed, needle feed, alternating upper foot
feed and large hook.

868-190322 Single-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.
Function keys for: manually sewing backward,
needle high/low /single stitch, switching on/off of the
bartack, 2nd stitch length, switching on/off of the
supplementary thread tension .

868-290322 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.
Function keys for: manually sewing backward,
needle high/low /single stitch, switching on/off of the
bartack, 2nd stitch length, switching on/off of the
supplementary thread tension.

6

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.
Function keys for: manually sewing backward,
needle high/low /single stitch, switching on/off of the
bartack, 2nd stitch length, switching on/off of the
supplementary thread tension.

GB

7

4. Optional equipments

For the 868 the following optional equipments are available:

Order No. Optional equipment Subclasses

868-190020

868-290020

868-190322

868-290322

868-390322

0867 590014 Electro-pneumatic needle cooler x

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 sewing lamp LEDs x x o o o

9850 001089 Power supply complete for x x o o o

integrated sewing lamp LEDs

N800 080001 Edge guide, swivelling x x

N800 080004 Roller stop x x

N800 080021 Edge guide, swivelling x x

N800 005650 Seam center guide x x

N800 005655 Seam center guide, swivelling x x

No. according Tape guide with tape-reel bracket x x
to the band size

9805 791113 USB memory key

for transferring data with the x x x x x
Efka control unit DA321G

0797 003031 Pneumatic connection package x x x x

0867 590354 Pneumatic sewing foot lifting x x

Stands

MG55 400364 Stand set MG 55-3 x x x x x

for motor fitting beneath the table,
with pedal
Table top size 1060 x 600 mm

MG55 400374 Stand set MG 55-3 x x x

for motor fixed on machine head,
with Pedal
Table top size 1060 x 600 mm

x = Optional equipment

o = Standard equipment

8

Please contact our Application Center (APC) for further optional
equipment.

E-Mail: [e-mail]

Further available documents concerning the class 868:

0791 868801 Parts list

0791 868641 Service Instructions

0791 100700 Fitting Instructions for Sewing Lamp LED

0791 867701 Instructions for fitting seam center guide

N800 005655 (mechanically)
N800 005650 (pneumatically)

0791 867704 Instructions for fitting pneumatic

sewing foot lift

0791 867705 Instructions for fitting for edge guide N800 080021

GB

9

5. Technical data

Noise: Workplace-related emission value in accordance with DIN 45635-48-A-1-KL2

868-190020 LC = _dB (A)

Stitch length: _ mm Sewing foot stroke: mm Speed: ____ min

Material:

868-290020 LC = _dB (A)

Stitch length: _ mm Sewing foot stroke: mm Speed: ____ min

Material:

868-190322 LC = _dB (A)

Stitch length: _ mm Sewing foot stroke: mm Speed: ____ min

Material:

868-290322 LC = _dB (A)

Stitch length: _ mm Sewing foot stroke: mm Speed: ____ min

Material:

868-390322 LC = _dB (A)

Stitch length: _ mm Sewing foot stroke: mm Speed: ____ min

Material:

-1

-1

-1

-1

-1

10

5.1 Technical data subclasses

868-190020

868-190322

868-290020

868-290322

Type of stitch Lockstitch 301

Hook type

large

large

large

large

Number of needles 1 2 1 2 1

Needle system 134-35

Needle size 170
(depending on E-No.) [Nm]

Max. thread thickness [Nm] 10 / 3

Stitch length [mm]

- Forward 12

- Backward 12

868-390322

large

GB

Number adj. stitch lengths 1 2 1 2 2

Max. speed [min-1] 2500 2500 2500 2500 2500

Speed with
factory setting [min

-1

] 2500 2500 2500 2500 2500

Max. lifting height [mm] 20* 20* 20* 20* 20*
(*only with turn-back device)

Max. sewing foot stroke [mm] 9 9 9 9 9

Operating pressure [bar] - 6 - 6 6

Air consumption per
working cycle [NL] - 0,7 - 0,7 0,7

Dimensions (H x W x D) [mm] 690 / 220 / 640

Weight 68 68 70 70 68
with direct drive [kg] - 72 - 74 72

11

11

10

Threading scheme single-needle machine

1

2

3

9

4

8

5

7

6

0868 190xxx 0868 390xxx

Threading scheme double-needle machine

-

22

12

13

21

14

15

20

16

12

19

18

17

6. Operation

6.1 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.

–

–

–

–

–

–

–

–

Threading in the needle thread with double-needle machines

–

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.

Conduct the thread counter-clockwise around the supplementary
tensioner wheel 4.

Conduct the thread clockwise around the main tensioner wheel 5.
Pull the thread underneath the thread take-up spring 8 and conduct

it through the thread regulator 10 to the thread lever 11.
Conduct the thread through the thread lever 11 and the threading

guides 9, 7 and 6 on the needle bar.

Thread the thread into the needle eye.

GB

Put the thread reels 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 for the left needle (as with single-needle machines)

–

Thread in the thread through threading guide 1 and 2.

–

Conduct the thread clockwise around the pre-tensioner 3.

–

Conduct the thread counter-clockwise around the supplementary
tensioner 4.

–

Conduct the thread clockwise around the main tensioner 5.

–

Pull the thread underneath the thread take-up spring 8 and conduct
it through the thread regulator 10 to the thread lever 11.

–

Conduct the tread through the upper bore hole of the thread
lever 11 and the threading guides 9, 7 and 6 on the needle bar.

–

Thread the thread into the needle eye.

Thread for the right needle

–

Thread in the thread through threading guide 12 and 13.

–

Conduct the thread clockwise around the pre-tensioner 14.

–

Conduct
tensioner 15.

–

Conduct the thread clockwise around the main tensioner 16.

–

Pull the thread underneath the thread take-up spring 19 and
conduct it through the thread regulator 21 to the thread lever 22.

–

Conduct the thread through the lower bore hole of the thread
lever 22 and the threading guides 20, 18 and 17 on the needle bar.

–

Thread the thread into the eye of the right needle.

the thread counter-clockwise around the supplementary

13

321

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. C: Needle-thread tension too high

or

hook-thread tension too low

54

14

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 w ith the bolt 5.

–

To shorten the starting thread:
Turn knurled nut 4 clockwise.

–

To lengthen the starting thread:
Turn knurled nut 4 counterclockwise.

Main tensioner

The main tensioner 2 should be set to the minimum possible tension.

The looping of the threads must be in the center of the material.
With thin material excessive thread tension can cause unwanted
gathering and thread breakage.

–

Adjust the main tensioner 2 so that the stitches are uniform.
To increase tension: turn the knurled nut clockwise
To decrease tension: turn the knurled nut anti-clockwise

GB

Supplementary tensioner

The supplementary tensioner 3 can be switched in to effect a rapid
change in needle-thread tension during operation (e.g. with thickened
seams).

–

Set the supplementary tensioner 3 lower than the main tensioner 2.

15

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".

Sewing foot lifting

withing a seam

Parameter

setting

F-196=0 0000

F-196=0 1100

F-196=0 0011

F-196=0 1111

1 = Thread tension opened mechanically

0 = Thread tension c losed mechanically

If the thread’ s supplementary tension is opened, this condition will

·

be maintained when lifting the sewing foot.

When switching the machine off, the last setting of the thread’s

·

supplementary tension will be maintained through the mains
connection.

Thread main

tension

Thread

supplement.

tension

Sewing foot lifting

after thread trimming

Thread main

tension

Thread

supplement.

tension

6.2.2 Reparation seam with thread tension always closed

Only Efka DC 1550 DA 321G

When executing a reparation seam, the thread tension is to stay closed
during the lifting of the sewing foot. Then the setting of the parameter
F-196 for the function of the thread main tension and the thread
supplementary tension in relation to the sewing foot lifting is not active.

For a quick switching on and off of the reparation seam, a parameter
setting first has to be carried out.

Programming the reparation seam with key “A” of the Efka

·

operating panel V810/V820: Set the parameter F-293 to 18.

Programming the reparation seam with the key “B” of the Efka

·

operating panel V810/V820: Set the parameter F-294 to 18.

By actuating the key “A” or “B” on the Efka operating panel V810 or
V820, the reparation seam, with the thread tension being always
closed, can be switched on and off quickly.

If the reparation seam mode was switched on, at the end of the
reparation seam it has to be switched off by actuating the same key of
the Efka operating panel, in order to activate the parameter F-196
again.

16

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 stroke adjustment max. stroke adjustments
Setting via knee switch setting wheel

Reaching of the HP-speed

of parameter F-117

(Speedomat)

F-197 = 0 1 1

F-197 = 1 0 1

F-197 = 2 1 (*) 0

F-197 = 3 0 0

(*) If the stroke adjustment (max. via knee switch is switched on and
the HP-speed of parameter F-117 is reached through the “Speedomat”,
the thread’s supplementary tension will be switched on automatically.

0 = Thread’s supplementary tension closed mechanically

1 = Thread’s supplementary tension opened mechanically

GB

·

·

Basic control box setting for the automatic steps of the
stitch-number-reduction (Speedomat) through the setting wheel for the
height of the alternating transport stroke

Parameter 188

Step 01-21 total Speedomat range

Step 01-10 max. allowed number of stitches. parameter

Step 11-18 linear stepwise reduction of the max. number of

Step 19-21 max. allowed number of stitches, parameter

6.3 Opening the thread tension

Subclasses
868-190020, 868-290020

When lifting the sewing feet with the knee switch, main and
supplementary tension are automatically opened.

If the thread’s supplementary tension is closed, the condition will
be maintained when adjusting the stroke.

When the machine is switched off, the last setting of the thread’s
supplementary tension will be maintained through the mains
connection.

F-111 = = 2500min

stitches (Speedomat)

F-117 = 1.600 min

-1

-1

Subclasses
868-190322, 868-290322, 0868-390322

The thread tension is automatically opened when trimming the thread.

17

6.4 Short stitch

The short stitch can be set mechanically forward as well as backward.
The short stitch is s et 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.

The function is switched on by setting the parameter F-136 to “4" while
the “Soft-Start” parameter F-134 is set to “1".

6.4.2 Short stitch at the end of a seam

At the end of a seam the function “Short Thread trimming” (FA-STL)
can be switched on. This function guarantees a safe thread trimming
with stitch lengths above 6 mm.

The function “Short Thread trimming” is switched on by setting the
Parameter F-136 to “2" w ith the Efka control unit.

6.4.3 Short stitch at the seam beginning and seam end

This function is switched on by setting the parameter F-136 to “3" while
the ”Soft-Start" parameter F-134 is set to “1".

18

1

1

2

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.

GB

19

6.6 Adjusting the thread regulator

32 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.
Thread regulator to the left = more thread.
Thread regulator to the r ight = less thread.

–

Tighten screw 2.

Adjustment information:

If the maximum quantity of thread is required the thread-tensioning
spring 3 must be pulled upwards about 0.5 mm from its lower limit
position. This is the case when the needle-thread loop passes the
maximum hook diameter.

20

6.7 Winding on the hook thread

543 21

–

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.

–

Sewing
The bobbin-winder lever terminates the process as soon as the
bobbin is full.
The bobbin winder always stops in such a position that the blade 6
is in the insertion position (see right-hand illustration).

–

Remove the full bobbin 1, place the thread behind the blade 6 and
sever it (in the arrow direction).

–

Fit empty bobbin onto the bobbin winder for the next winding
process and press the bobbin-winder lever 2 into the bobbin.

Caution Danger of breakage!

If the thread is not to be wound on during sewing, it is essential
for the sewing foot to be locked in the raised position and to set the
sewing-foot stroke to its smallest value.

26

GB

21

6.8 Changing the hook-thread bobbin

1

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.

–

Conduct the hook thread through the slot 3 and underneath the
spring 4.

–

Pull the hook thread through the slot 7 and continue pulling until it
stands out about 4.5 cm.

–

Close the flap 5 and pull the hook thread through the thread
guide 6 of the flap.

765 432

22

6.9 Setting the hook thread tension

12

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.
Increase the hook thread tension = Turn screw 1 clockwise

Decrease the hook thread tension = Turn screw 1 counterclockwise

GB

23

6.10 Inserting and changing the needle with single-needle machines

21

Caution: danger of injury !

Turn off the main switch.

The needle may only be changed with the sewing machine switched
off.

1

2

3

–

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.

–

Tighten screw 2.

CAUTION!

When changing to another needle size, the distance between hook
and needle must be readjusted (see service instructions).

Ignoring the above mentioned hint can cause the following mistakes:

When inserting a thinner needle:
–

Missed stitches
Damage of the thread

When inserting a thicker needle:
–

Damage of the hook tip
Damage of the needle

24

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.

Attention!

Seen from the operating side, the needle scarf 4 of the right needle
must point to the right side and the needle scarf of the left needle
point to the left side (see drawing).

–

Tighten screw 3.

CAUTION!

When changing to another needle size, the distance between hook
and needle must be readjusted (see service instructions).

Ignoring the above mentioned hint can cause the following mistakes:

GB

When inserting a thinner needle:
–

Missed stitches
Damage of the thread

When inserting a thicker needle:
–

Damage of the hook tip
Damage of the needle

25

6.12 Lifting the sewing foot

21

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.
The sewing foot stays in the up position as long as pressure is
maintained on the knee lever 1.

Raising the sewing foot electro-pneumatically (pedal)

–

Press the pedal 2 half-way back.
The sewing feet are raised with the machine at a halt.

–

Press the pedal 2 all the way back.
The thread is severed and the sewing foot raised.

26

6.13 Locking the sewing feet in lifted position

1

6.14 Sewing-foot pressure

12

–

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.

Or
–

Lift the sewing feet pneumatically by pushing the knee switch.
The lever 1 then moves back into its initial position.

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.

–

To incr eas e the sewing-f oot pres sur e = turn the setting wheel 2

clockwise.

–

To decre ase the se win g-foo t p ressu re = turn the setting wheel 2

anti-clockwise.

GB

27

6.15 Sewing-foot stroke

21

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 s elected.

–

Turn the setting wheel 1 and 2 (1 to 9)
1 = minimal sewing foot stroke
9 = maximal sewing foot stroke

Automatic speed limitation
Machines without thread trimmer

With these machines the s peed is not controlled
Please take into consideration the hint and the chart on the next side.

Machines with thread trimmer

The sewing-foot stroke and speed are interdependent. A potentiometer
is linked mechanically with the adjusting wheel. By means of this
potentiometer the control unit detects what foot-stroke has been set
and restricts the speed of rotation accordingly.

3

28

Machines with electro-pneumatic rapid stroke adjustment

With fabric parts that are thicker or in order to sew over cross seams,
the increased sewing foot stroke (setting wheel 1) can be switched on
during the sewing process by actuating the knee switch 3 beneath the
table top.
As with the machines that are equipped with a thread trimmer, the
potentiometer is also available.

CAUTION Danger of breakage!

The standard sewing foot stroke that is set with the setting wheel 2
may never exceed the s troke set with the setting wheel 1.

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).

Operation mode

Keystroke

F-138 = off

Operation / Explanation

The maximum sewing foot stroke remains engaged as
long as the knee switch 3 is actuated.

F-184 = 0

Push-lock
F-138 = on

The maximum sewing foot stroke is engaged by
actuating the knee switch 3.
By actuating the knee switch once again the maximum
sewing foot stroke is disengaged.

Keystroke with
minimum
number of
stitches
F-138 = off
F-184 0 < 100

The maximum sewing foot stroke remains engaged as
long as knee switch 3 is actuated.
After releasing the knee switch the machine sews with
maximum sewing foot stroke until the set minimum
number of stitches is reached (parameter F-184).
Then the seam is continued with normal sewing foot
stroke.

HINT !

In order to ensure an operation as safe as possible and a high
durability, the max. speed as shown in the chart should not been
exceeded.

GB

Subclasses Range of stitch lengths Sewing foot stroke max. speed

[mm] pos. of setting wheel [min

-1

]

0868-190322 0-8 1-2,5 2500

3 2400

0868-290322 4 2200

5 2000

0868-190020 6 1800

7-9 1600

0868-290020

8-12 1-9 1600

With double-needle machines having a needle distance of more than
20 mm, the max. speed may amount up to 2000 min

-1

.

29

6.16 Setting the stitch length

32 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. s titch length

–

Set the smaller stitch length with the lower setting wheel 2.
Setting 1 = min. stitch length
Setting 12 = max. s titch length

The stitch length are the same for both, forward and backward sewing.
–

For the manual sewing of tacks, push the stitch regulator lever 3
downward.
The machine sews backward stitches as long as the stitch
regulator lever 3 is pressed down.

30

Hint

In order to facilitate the setting of stitch lengths, the stitch length that
remains unchanged should be activated with key 2 (see chapter 6.17).

Caution Danger of breakage!

The stitch length set with the lower setting wheel 2 must not exceed
the stitch length set with the upper setting wheel 1.

6.17 Key pad on the machine arm

10

9

876 5 43 21

Key Function

1

2

3

4

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.

2ndstitch 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

Recalling or suppressing the initial or final bartack.
If the initial and final bartacks are generally switched
on, the next bartack is switched off by actuating the
key.
If the initial and final bartacks are generally switched
off, the next bartack is switched on by actuating the
key.

Setting the needle in h igh or low position.
The function of the key can be defined with the
parameter F-140.
1 = Needle high
2 = Needle high/low
3=Singlestitch
4=Singlestitchwith2
5 = Needle high, when outside position 2
The factory setting is 1 = Needle high.

nd

stitch length/ short stitch

GB

5

Manually sewing backward.
The machine sews backward stitches as long as the
key is being pushed.

31

LED Function

7 and 8

10

The function of key 9 canbeselectedwiththescrew6 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.

CAUTION!

Before key 9 can be programmed with a new function, the former
setting must be deactivated.

Display for empty bobbin with residual thread
monitor (left/ right bobbin)

LED display “power on"

7. Sewing drive and Operating Panel

For a detailed description of the sewing drive, please c onsult the
current issue of the operating manual of the motor manufacturer.

32

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 switch on.

–

The last s ewing procedure was completed with a final bartack and
thread trimming.

Operating and function sequence:

Sewing procedure Operation / Explanation

Prior to sewing

Starting position

Position material
for starting the seam.

Sewing

In mid-seam

Interrupt the sewing process

- Pedal in rest position.
The machine is at a halt.
Needle up.
The sewing feet are down..

- Pull pedal half-way back.
The sewing feet are raised.

- Push material forward until it touches the needle.

- Push pedal forwards and keep it pushed.
Subsequently the machine will continue sewing with the
rotation speed determined by the pedal.

- Release pedal (rest position).
The machine halts in the 1
(Needle down)
The sewing feet are down. .

st

position.

GB

Resume the sewing process
(after releasing the pedal)

- Push pedal forwards.
The machine sews at the speed of rotation set by
the pedal.

33

6

54 3 21

Sewing an intermediate bartack

Sewing over a cross seam.
(max. sewing foot stroke)

Sewing the 2

nd

stitch length during
thesewingprocess
(max. stitch length)

Increase the thread tension during
thesewingprocess

At the seam end

- 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.

The max. sewing foot stroke is switched on.
The rotation speed is limited to 1600 min

-1

.

Operation modes of the max. sewing foot stroke:

- Press briefly the knee switch to switch on the max.
sewing foot stroke.

- Actuate the knee switch again to switch off the max.
sewing foot stroke.

- Actuate key 2.

- Actuate key 1.

Remove the material

34

- Push the pedal all the way back and keep it pushed.
The final bartack will be sewn (if activated).
The thread will be trimmed.
The machine halts in the 2

nd

position.
The needles are lifted ( Turning back).
The sewing feet are lifted.

- Remove the material.

9. Maintenance

9.1 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.

12

Maintenance work Explanation Operating
to be carried out hours

Machine head

- Remove lint, pieces of thread
and other debris (e.g. w ith
an air blow gun)

Places in special need of cleaning:

- area under the throat plate 2

- feeders

- area around the hook 1

- bobbin housing

- thread trimmer

- needle areal

3

8

GB

Direct drive

Clean fan grille 3. (e.g. with an
air blow gun)

CAUTION !

Hold the air blow gun in a way that the lint
is not blown into the oil collector.

Remove lint and pieces of thread from
air-intake openings.

8

35

2

4

6

8

10

3

1

4

2

Maintenance work Explanation Operating
to be carried out hours

Sewing drive

Clean fan grille 2. (e.g. with
an air blow gun)

Check condition and
tension of V-belt 1.

Pneumatic system

Check water level in
pressure regulator.

Remove lint and pieces of thread from
air-intake openings.

It must be possible to depress the V-belt by
about 10 mm by pressing it with a finger at its
mid-point.

The water level must not rise to the level of
the filter cartridge 3.

- After unscrewing the drain screw 5,the

water under pressure will flow out of
the water separator 4.

8

160

40

5

Clean filter cartridge.

Check the system for leaks.

36

Dirt and condensation are separated out by
the filter cartridge 3.

- Disconnect the machine from the
compressed-air supply.

- Unscrew the drain screw 5.
Theremustbenopressureinthe
machine’s pneumatic system.

- Unscrew water separator 4.

- Unscrew filter cartridge 3.
Wash the filter shell and cartridge
with cleaning fluid (not solvent) and
blast clean.

- Re-assemble the maintenance unit.

500

500

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.

To lubricate the special sewing machine use only DA-10 lubricating oil
or an equivalent oil of the following specification:

–

Viscosity at 40° C: 10 mm²/s

–

Flashpoint: 150° C

DA-10 is available from DÜRKOPP ADLER AG retail outlets under the
following part numbers:

250-ml container: 9047 000011
1-liter container: 9047 000012
2-liter container: 9047 000013
5-liter container: 9047 000014

GB

Maintenance work Explanation Operating
to be carried out hours

Lubrication of the machine
head

The machine head is fitted with a central
oil-wick lubrication system.
The bearings are supplied out of oil
reservoir 1.

- The oil level must not fall below the
marking line 3 (MIN) of the oil reservoir.
If the oil level falls below the marking line 3,
the oil reservoir will be lit (only the
CLASSIC version).

- Fill in oil through the bore hole 2 up to the
markingline“Max”.

8

37

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.

21

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.

–

To set the contact pressure pull out the turning handle 2 of the
pressure regulating valve of the seam center guide and turn it.

In clockwise direction= to increase the contact pressure
In counter-clockwise direction = to reduce the contact pressure

38