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869-M PREMIUM
Service Instructions
Page 2
IMPORTANT
READ CAREFULLY BEFORE USE
KEEP FOR FUTURE REFERENCE
All rights reserved.
Property of Dürkopp Adler AG and protected by copyright. Any reuse of these contents,
including extracts, is prohibited without the prior written approval of Dürkopp Adler AG.
Copyright © Dürkopp Adler AG 2018
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Table of Contents
1 About these instructions ......................................................... 5
1.1 For whom are these instructions intended?................................ 5
1.2 Representation conventions – symbols and characters ............. 5
1.3 Other documents ........................................................................ 7
1.4 Liability........................................................................................ 7
2 Safety ......................................................................................... 9
2.1 Basic safety instructions ............................................................. 9
2.2 Signal words and symbols used in warnings ............................ 10
3 Working basis ......................................................................... 13
3.1 Order of the settings ................................................................. 13
3.2 Laying the cable guide.............................................................. 13
3.3 Calling up the service routine ................................................... 14
3.4 Removing the covers................................................................ 16
3.4.1 Access to the underside of the machine................................... 17
3.4.2 Removing and placing the arm cover ....................................... 18
3.4.3 Removing and placing the head cover ..................................... 19
3.4.4 Removing and placing the valve cover..................................... 20
3.4.5 Disassembling and assembling the throat plate slide............... 21
3.4.6 Disassembling and assembling the throat plate ....................... 22
3.4.7 Disassembling and assembling the feed dog ........................... 23
3.5 Flats on shafts .......................................................................... 24
3.6 Locking the machine in place ................................................... 25
4 Setting the handwheel scale.................................................. 27
5 Positioning the arm shaft....................................................... 28
6 Positioning the toothed belt wheels ..................................... 29
6.1 Positioning the upper toothed belt wheel.................................. 30
6.2 Positioning the lower toothed belt wheel .................................. 31
7 Setting the mechanical stitch adjustment............................ 32
7.1 Setting the stitch regulator gear................................................ 32
7.2 Setting the eccentric for the forward and backward stitches .... 35
8 Setting the feed dog ............................................................... 36
8.1 Setting the feed dog position .................................................... 36
8.2 Setting the feed dog movement................................................ 38
8.2.1 Setting the feed dog feed movement........................................ 38
8.2.2 Setting the feed dog height at top dead center......................... 40
8.2.3 Setting the feed dog stroke movement..................................... 41
9 Aligning the needle bar linkage............................................. 42
9.1 Aligning the needle bar linkage sideways................................. 42
9.2 Aligning the needle bar linkage in the sewing direction............ 44
10 Position of the hook and needle ........................................... 46
10.1 Setting the hook side clearance................................................ 46
10.2 Setting the loop stroke position................................................. 48
10.3 Setting the needle guard........................................................... 49
10.4 Setting the needle bar height.................................................... 50
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11 Setting the bobbin case lifter ................................................ 52
12 Sewing Feet............................................................................. 54
12.1 Setting the sewing foot lifting gear............................................ 54
12.2 Setting an even sewing foot stroke........................................... 55
12.3 Setting the stroke movement for the feeding foot..................... 56
12.4 Setting the sewing foot pressure and sewing foot lift................ 58
13 Adjusting the thread tensioning plate .................................. 60
13.1 Setting the machine .................................................................. 60
13.2 Adjusting the tensioning plate................................................... 61
13.2.1 Adjusting the tensioning plate using the Schmidt MST-2000 ......61
13.2.2 Adjusting the tensioning plate using a mechanical
thread scale .............................................................................. 63
13.3 Checking the adjusted thread tension ...................................... 64
13.3.1 Checking the adjusted thread tension using
the Schmidt MST-2000 ............................................................. 64
13.3.2 Checking the adjusted thread tension using a mechanical
thread scale .............................................................................. 66
14 Setting the needle thread tension ......................................... 68
14.1 Setting the needle thread regulator .......................................... 68
14.2 Setting the thread tension spring.............................................. 69
14.3 Electronic needle thread tension .............................................. 70
15 Winder...................................................................................... 71
15.1 Setting the winder ..................................................................... 71
15.2 Setting the hook thread guide................................................... 74
16 Thread cutter........................................................................... 75
16.1 Setting the height of the thread-pulling knife ............................ 75
16.2 Setting the cutoff curve............................................................. 76
16.3 Setting the cutting pressure ...................................................... 78
16.4 Setting point in time for cutting ................................................. 79
17 Setting the safety snap-on coupling..................................... 80
17.1 Attaching the safety snap-on coupling...................................... 80
17.2 Setting the torque ..................................................................... 81
18 Integrated motor ..................................................................... 82
18.1 Overview of the components .................................................... 82
18.2 Disassembling the drive............................................................ 83
18.2.1 Disassembling the handwheel and handwheel flange.............. 83
18.2.2 Removing the cover.................................................................. 83
18.2.3 Disassembling the encoder ...................................................... 84
18.2.4 Disassembling the stator .......................................................... 84
18.2.5 Disassembling the rotor ............................................................ 85
18.3 Assembling the drive ................................................................ 86
18.3.1 Assembling the rotor................................................................. 86
18.3.2 Assembling the stator ............................................................... 87
18.3.3 Assembling the encoder ........................................................... 88
18.3.4 Assembling the cover ............................................................... 88
18.3.5 Locking the machine in place ................................................... 89
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18.3.6 Assembling the handwheel flange............................................ 89
18.3.7 Assembling the handwheel....................................................... 90
19 Programming .......................................................................... 91
19.1 Calling up the Technician level................................................. 91
19.2 Structure of the software........................................................... 91
19.3 Lock technician level (Lock Techn.) submenu...................... 92
19.4 ParameterCall submenu...................................................... 92
19.5 Default Program submenu.................................................. 94
19.5.1 Setting the Stitch length (Stitchlen.) parameter ................. 94
19.5.2 Setting the Foot pressure (Foot Press.) parameter............. 95
19.5.3 Setting the Needle thread tension (Thr.Tens.) parameter .......95
19.5.4 Setting the Sewing foot stroke (Foot Stroke) parameter...... 95
19.5.5 Setting the Start bartack (Start Tack) parameter................. 96
19.5.6 Setting the End bartack (End Tack) parameter ...................... 96
19.5.7 Setting the Thread cutter (Thread Trim) parameter.............. 96
19.5.8 Setting the Daily pieces counter (DailyPieces) parameter......96
19.6 Machine config. submenu.................................................. 97
19.6.1 Setting the Thread cutter (Thread Trim) parameter.............. 98
19.6.2 Setting the Thread clamp (Thread Clamp) parameter........... 99
19.6.3 Setting the Speed (Speed) parameter.................................... 101
19.6.4 Setting the Stop positions (Stop Positions) parameter ...... 101
19.6.5 Setting the Sewing foot (Foot) parameter ............................. 102
19.6.6 Setting the Needle thread tension (Thr.Tens.) parameter .... 102
19.6.7 Setting the Sewing foot stroke (Stroke) parameter .............. 103
19.6.8 Setting the Stitch length (Stitchlen.) parameter ............... 104
19.6.9 Setting the Bobbin (Bobbin) parameter................................. 104
19.6.10 Setting the Motor holding force (Holding Force)
parameter ............................................................................... 105
19.6.11 Setting the Pedal (Pedal) parameter..................................... 106
19.6.12 Setting the Needle cooling (NeedleCooling) parameter ....... 106
19.6.13 Setting the Seam center guide (Center Guide) parameter... 107
19.6.14 Setting the Puller (Puller) parameter................................... 107
19.6.15 Setting the Edge guide (EdgeGuide) parameter ................... 109
19.6.16 Setting the Material thickness detection
(FabricThickness) parameter............................................ 109
19.6.17 Setting the Correction of effects of high speed
(Speed Corr.) parameter .................................................... 11
19.6.18 Setting the Light barrier (LightBarrier) parameter............ 110
19.6.19 Setting the Segment length (Mode Seg.Size) parameter ..... 111
19.6.20 Setting the Threading mode (Threading) parameter ........... 111
19.6.21 Setting the Operation lock (MachineBlockage) parameter ... 111
19.7 User config. submenu ...................................................... 111
19.7.1 Setting the Language selection (Language) parameter ........ 112
19.7.2 Setting the Parameter View (ParameterView) parameter ... 112
19.7.3 Setting the Input configuration (Input Config) parameter ... 113
19.7.4 Setting the Output configuration (Output Config)
parameter ............................................................................... 115
19.7.5 Setting the Additional inputs/outputs (Add I/O) parameter..... 116
19.7.6 Setting the barcode scanner (Scanner) parameter............... 119
19.7.7 Setting the Interface (Interface) parameter ....................... 119
19.7.8 Setting the Stitch functions (StitchFunctions) parameter..... 119
0
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19.7.9 Setting the Programs (Programs) parameter........................ 120
19.7.10 Setting the Electronic handwheel (Jog-Dial) parameter ..... 120
19.7.11 Setting the Access rights (Lock) parameter........................... 121
19.7.12 Setting the QONDAC (QONDAC) parameter ............................ 122
19.7.13 Setting the Fast menu keys (FastMenuKeys) parameters.... 122
19.7.14 Setting the Contrast (Contrast) parameter.......................... 123
19.7.15 Setting the Brightness (Brightness) parameter .................. 123
19.8 Service submenu................................................................. 124
19.8.1 Setting the Multitest (Multitest) parameter........................ 124
19.8.2 Setting the Service routine (Adjustments) parameter ......... 128
19.8.3 Setting the Calibration (Calibration) parameter................ 128
19.8.4 Displaying the Error list (Error Log) parameter................... 131
19.9 Counter submenu................................................................. 131
19.10 Reset data (Reset) submenu ................................................ 131
19.11 Data Transfer submenu .................................................... 132
19.11.1 Setting the All data (All Data) parameter............................ 133
19.11.2 Setting the Only data (Only Data) parameter...................... 134
19.11.3 Setting the Programs (Programs) parameter........................ 135
19.11.4 Saving the Error list (Error Log) parameter ........................ 137
19.12 Performing a software update................................................. 137
20 Maintenance .......................................................................... 141
20.1 Cleaning.................................................................................. 142
20.2 Lubricating .............................................................................. 143
20.2.1 Lubricating the machine head................................................. 144
20.2.2 Checking the hook lubrication................................................. 145
20.3 Servicing the pneumatic system ............................................. 146
20.3.1 Setting the operating pressure................................................ 146
20.3.2 Draining the water condensation ............................................ 147
20.3.3 Cleaning the filter element...................................................... 148
20.4 Parts list .................................................................................. 149
21 Decommissioning................................................................. 151
22 Disposal................................................................................. 153
23 Troubleshooting ................................................................... 155
23.1 Customer Service ................................................................... 155
23.2 Errors in sewing process ........................................................ 156
23.3 Messages of the software....................................................... 158
23.4 Error in the software ............................................................... 164
23.5 Testing the function of the buttons.......................................... 164
24 Technical data....................................................................... 167
25 Appendix ............................................................................... 169
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About these instructions
1 About these instructions
These instructions have been prepared with utmost care. They contain
information and notes intended to ensure long-term and reliable operation.
Should you notice any discrepancies or if you have improvement requests,
then we would be glad to receive your feedback through Customer
Service ( p. 155).
Consider the instructions part of the product and store them in a place
where they are readily available.
1.1 For whom are these instructions intended?
These instructions are intended for:
With regard to minimum qualification and other requirements to be met by
personnel, please also follow the chapter Safety ( p. 9).
• Specialists:
This group has the appropriate technical training for performing
maintenance or repairing malfunctions.
1.2 Representation conventions – symbols and characters
Various information in these instructions is represented or highlighted by the
following characters in order to facilitate easy and quick understanding:
Proper setting
Specifies proper setting.
Disturbances
Specifies the disturbances that can occur from an incorrect setting.
Cover
Specifies which covers must be disassembled in order to access the
components to be set.
Steps to be performed when operating the machine (sewing and
equipping)
Steps to be performed for service, maintenance, and installation
Steps to be performed via the software control panel
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About these instructions
1.
2.
…
•
The individual steps are numbered:
First step
Second step
The steps must always be followed in the specified order.
Lists are marked by bullet points.
Result of performing an operation
Change to the machine or on the display/control panel.
Important
Special attention must be paid to this point when performing a step.
Information
Additional information, e.g. on alternative operating options.
Order
Specifies the work to be performed before or after a setting.
References
Reference to another section in these instructions.
Safety Important warnings for the user of the machine are specifically marked.
Since safety is of particular importance, hazard symbols, levels of
danger and their signal words are described separately in the chapter
Safety ( p. 9).
Location
information
If no other clear location information is used in a figure, indications of right
or left are always from the user's point of view.
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About these instructions
1.3 Other documents
The machine includes components from other manufacturers. Each manufacturer has performed a hazard assessment for these purchased parts
and confirmed their design compliance with applicable European and national regulations. The proper use of the built-in components is described
in the corresponding manufacturer's instructions.
1.4 Liability
All information and notes in these instructions have been compiled in
accordance with the latest technology and the applicable standards and
regulations.
Dürkopp Adler cannot be held liable for any damage resulting from:
• Breakage and damage during transport
• Failure to observe these instructions
• Improper use
• Unauthorized modifications to the machine
• Use of untrained personnel
• Use of unapproved parts
Transport
Dürkopp Adler cannot be held liable for breakage and transport damages.
Inspect the delivery immediately upon receiving it. Report any damage
to the last transport manager. This also applies if the packaging is not
damaged.
Leave machines, equipment and packaging material in the condition in
which they were found when the damage was discovered. This will ensure
any claims against the transport company.
Report all other complaints to Dürkopp Adler immediately after receiving
the product.
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About these instructions
8 Service Instructions 869-M PREMIUM - 00.0 - 07/2018
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Safety
2 Safety
This chapter contains basic information for your safety. Read the instructions carefully before setting up or operating the machine. Make sure to
follow the information included in the safety instructions. Failure to do so
can result in serious injury and property damage.
2.1 Basic safety instructions
The machine may only be used as described in these instructions.
These instructions must be available at the machine's location at all times.
Work on live components and equipment is prohibited. Exceptions are
defined in the DIN VDE 0105.
For the following work, switch off the machine at the main switch or
disconnect the power plug:
• Replacing the needle or other sewing tools
• Leaving the workstation
• Performing maintenance work and repairs
• Threading
Missing or faulty parts could impair safety and damage the machine.
Only use original parts from the manufacturer.
Transport Use a lifting carriage or forklift to transport the machine. Raise the machine
max. 20 mm and secure it to prevent it from slipping off.
Setup The connecting cable must have a power plug approved in the relevant
country. The power plug may only be assembled to the power cable by
qualified specialists.
Operator's
obligations
Follow the country-specific safety and accident prevention regulations and
the legal regulations concerning industrial safety and the protection of the
environment.
All the warnings and safety signs on the machine must always be in legible
condition. Do not remove!
Missing or damaged warnings and safety signs must be replaced
immediately.
Requirements
to be met by
the personnel
Only qualified specialists may:
• Setting up the machine
• Performing maintenance work and repairs
• Performing work on electrical equipment
Only authorized persons may work on the machine and must first have
understood these instructions.
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Safety
Operation Check the machine during operating for any externally visible damage.
Stop working if you notice any changes to the machine. Report any changes
to your supervisor. Do not use a damaged machine any further.
Safety equipment Safety equipment should not be removed or deactivated. If it is essential
to remove or deactivate safety equipment for a repair operation, it must be
assembled and put back into operation immediately afterward.
2.2 Signal words and symbols used in warnings
Warnings in the text are distinguished by color bars. The color scheme is
based on the severity of the danger. Signal words indicate the severity of
the danger.
Signal words Signal words and the hazard they describe:
Signal word Meaning
DANGER (with hazard symbol)
If ignored, fatal or serious injury will result
WARNING (with hazard symbol)
If ignored, fatal or serious injury can result
CAUTION (with hazard symbol)
If ignored, moderate or minor injury can result
CAUTION (with hazard symbol)
If ignored, environmental damage can result
NOTICE (without hazard symbol)
If ignored, property damage can result
Symbols The following symbols indicate the type of danger to personnel:
Symbol Type of danger
General
Electric shock
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Safety
Symbol Type of danger
Puncture
Crushing
Environmental damage
Examples Examples of the layout of warnings in the text:
DANGER
Type and source of danger!
Consequences of non-compliance.
Measures for avoiding the danger.
This is what a warning looks like for a hazard that will result in serious
injury or even death if ignored.
WARNING
Type and source of danger!
Consequences of non-compliance.
Measures for avoiding the danger.
This is what a warning looks like for a hazard that could result in
serious or even fatal injury if ignored.
CAUTION
Type and source of danger!
Consequences of non-compliance.
Measures for avoiding the danger.
This is what a warning looks like for a hazard that could result in
moderate or minor injury if the warning is ignored.
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Safety
CAUTION
Type and source of danger!
Consequences of non-compliance.
Measures for avoiding the danger.
This is what a warning looks like for a hazard that could result in envi-
ronmental damage if ignored.
NOTICE
Type and source of danger!
Consequences of non-compliance.
Measures for avoiding the danger.
This is what a warning looks like for a hazard that could result in
property damage if ignored.
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Working basis
3 Working basis
3.1 Order of the settings
Order
The setting positions for the machine are interdependent.
Always comply with the order of individual setting steps as specified.
It is absolutely essential that you follow all notices regarding prerequisites
and subsequent settings that are marked with in the margin.
NOTICE
Property damage may occur!
Risk of machine damage from incorrect order.
It is essential to follow the working order specified in these
instructions.
3.2 Laying the cable guide
Ensure that all cables are laid in the machine such that the function of
moving parts is not hampered.
To lay the cable guide:
1. Lay any excess cabling neatly in proper cable snakes.
2. Bind together the cable loops with cable ties.
Important
Tie loops wherever possible to fixed parts.
The cables must be secured firmly.
3. Cut off any overlapping cable ties.
NOTICE
Property damage may occur!
Excess cables can impair the functioning of moving machine parts.
This impairs the sewing function and can result in damage.
Lay excess cable as described above.
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Working basis
3.3 Calling up the service routine
The machine must remain switched on for the following settings,
as switching off will delete the required programmed values:
• Disassembling and assembling the feed dog
• Setting the feed dog
• Setting the feed dog feed movement
• Aligning the needle bar linkage
• Setting the loop stroke position
• Setting the needle bar height
• Setting an even sewing foot stroke
• Setting the stroke movement for the feeding foot
Call up the corresponding service routine to be able to make settings on
the active machine without any risk. In the service routine, the machine
moves to the correct position and the power is switched off as soon as the
Service Stop button is pressed. The settings are preprogrammed and
changes are not possible.
To call up the service routine:
1. Switch on the machine.
2. Press the P and S buttons at the same time.
3. Input the password (25483).
The service menu is active.
4. Select the required service routine in the Service > Settings
menu item.
Settings
Feed dog Assemble (assembling and removing feed dog)
PosToNeedle (setting the feed dog)
Movement (setting the feed dog feed movement)
Needle-Hook Timing (setting the loop stroke position)
Needlebar (setting the needle bar)
Stroke Equal Stroke (setting an even sewing foot stroke)
Feed Move (setting the stroke movement for the feeding foot)
5. Confirm with OK.
The display shows all the values set in the selected service routine.
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Working basis
Fig. 1: Calling up the service routine (1)
Gleichm.Hub
0.0
0 30
6. Press button 7.
A request appears to press the Service Stop button.
Fig. 2: Calling up the service routine (2)
Gleichm.Hub
Service Stopp drücken
7. Press the Service Stop button.
The machine moves to the programmed position and is switched off.
The button lights up.
The display shows the information that the Service Stop is active.
Fig. 3: Calling up the service routine (3)
Gleichm.Hub
Service Stopp aktiv
8. Make the required settings.
9. Press the Service Stop button.
The power is switched on again.
The button turns off.
The display shows a warning.
Fig. 4: Calling up the service routine (4)
Gleichm.Hub
Füße absenken - OK
10. Press the OK button.
You are now in the service menu again.
11. To exit the menu, press the ESC button.
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3.4 Removing the covers
WARNING
Risk of injury from moving parts!
Crushing possible.
Move the machine to the service position or switch
the machine off before removing the covers.
WARNING
Risk of injury from sharp parts!
Puncture possible.
Move the machine to the service position or switch
the machine off before removing the covers.
Working basis
For many types of setting work, you will have to remove the machine
covers first in order to access the components.
This chapter describes how to remove and then assemble the individual
covers again. The text for each type of setting work then specifies only the
cover that needs to be removed at that particular time.
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Working basis
①
②
③
3.4.1 Access to the underside of the machine
To access the components on the underside of the machine, swivel up
the machine head.
Fig. 5: Tilting the machine head
(1) - Machine head
(2) - Bartack
Tilting the machine head
To tilt the machine head:
1. Lift the lever (3).
2. Tilt the machine head (1) as far as it will go.
Erecting the machine head
To erect the machine head:
1. Erect the machine head (1).
For safety reasons, the machine head (1) is stopped by the bolt (2).
2. Lift the lever (3) and erect the machine head (1) completely.
(3) - Lever
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3.4.2 Removing and placing the arm cover
②
①
Fig. 6: Removing and placing the arm cover
(1) - Arm cover (2) - Screws
Removing the arm cover
To remove the arm cover:
Working basis
1. Loosen the screws (2).
2. Remove the arm cover (1).
Placing the arm cover
To place the arm cover:
1. Place the arm cover (1).
2. Tighten the screws (2).
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Working basis
①
②
3.4.3 Removing and placing the head cover
Fig. 7: Removing and placing the head cover
(1) - Head cover (2) - Screws
Removing the head cover
To remove the head cover:
1. Loosen the screws (2).
2. Remove the head cover (1).
Placing the head cover
To place the head cover:
1. Place the head cover (1).
2. Tighten the screws (2).
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3.4.4 Removing and placing the valve cover
①
②
Fig. 8: Removing and placing the valve cover
Working basis
(1) - Valve cover (2) - Screws
Important
When removing and positioning the valve cover, be sure not to pull off
any cables.
Removing the valve cover
To remove the valve cover:
1. Loosen the screws (2).
2. Remove the valve cover (1).
Placing the valve cover
To place the valve cover:
1. Place the valve cover (1).
2. Tighten the screws (2).
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Working basis
① ①
②②
3.4.5 Disassembling and assembling the throat plate slide
Fig. 9: Disassembling and assembling the throat plate slide
(1) - Throat plate slide (2) - Screws
Disassembling the throat plate slide
To disassemble the throat plate slide:
1. Loosen the screws (2).
2. Remove the throat plate slide (1).
Assembling the throat plate slide
To assemble the throat plate slide:
1. Place the throat plate slide (1).
2. Tighten the screws (2).
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3.4.6 Disassembling and assembling the throat plate
①②
Fig. 10: Disassembling and assembling the throat plate
(1) - Screw (2) - Throat plate
Working basis
Disassembling the throat plate
To disassemble the throat plate:
1. Execute the service routine Feed dog > PosToNeedle
( p. 14).
The software is used to define the necessary presettings on
the machine.
2. Loosen the screw (1).
3. Remove the throat plate (2).
4. Finish the service routine.
Assembling the throat plate
To assemble the throat plate:
1. Execute the service routine Feed dog > PosToNeedle
( p. 14).
The software is used to define the necessary presettings on
the machine.
2. Insert the throat plate (2).
3. Tighten the screw (1).
22 Service Instructions 869-M PREMIUM - 00.0 - 07/2018
4. Finish the service routine.
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Working basis
②
①
3.4.7 Disassembling and assembling the feed dog
Fig. 11: Disassembling and assembling the feed dog
(1) - Feed dog (2) - Screw
Proper setting
The feed dog does not touch the throat plate with the maximum
permissible stitch length.
Disassembling the feed dog
To disassemble the feed dog:
1. Execute the service routine Feed dog > Assemble ( p. 14).
The software is used to define the necessary presettings on the
machine.
Important
The maximum permissible stitch length can be set in the service routine.
Enter the maximum permissible stitch length before pressing the button 7.
1. Disassemble the throat plate ( p. 22).
2. Loosen the screw (2).
3. Remove the feed dog (1).
Assembling the feed dog
To assemble the feed dog:
1. Place the feed dog (1).
2. Tighten the screw (2).
3. Insert the throat plate ( p. 22).
4. Finish the service routine.
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Working basis
②
①
Important
The machine needs to be restarted after a change of the maximum stitch
length.
If necessary, set the maximum permissible stitch length via the software.
Check the feed dog position in its movement at maximum stitch length
(depending on the equipment: 6, 7 or 9) by turning the handwheel.
The feed dog must not hit against the throat plate.
Order
Then check the following setting:
• Feed dog ( p. 36)
3.5 Flats on shafts
Fig. 12: Flats on shafts
(1) - Flat (2) - Shaft
Some shafts have flat surfaces at the points where the components are
screwed on. This stabilizes the connection and makes setting easier.
Important
Always ensure that the screws are completely flush with the surface.
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Working basis
①②③
④
3.6 Locking the machine in place
Fig. 13: Locking the machine in place(1)
(1) - Large arresting groove
(2) - Small arresting groove
(3) - Locking peg
For some settings, the machine must be locked in place. To do this, the
locking peg from the accessory pack is inserted into a slot on the arm shaft
crank, blocking the arm shaft.
There are 2 securing positions:
• Position 1: Loop stroke position
• 5 mm end in the large arresting groove (1)
• Setting the loop stroke and needle bar height
• Position 2: Handwheel zero position
• 3 mm end in the small arresting groove (2)
• Setting the handwheel position and checking the top dead center
for the needle bar
Fig. 14: Locking the machine in place(2)
(4) - Locking opening
Locking the machine in place
To lock the machine in place:
1. Remove the plug from the locking opening (4).
Service Instructions 869-M PREMIUM - 00.0 - 07/2018 25
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Working basis
2. Turn the handwheel until the appropriate arresting groove (1) or (2) is
in front of the locking opening (4):
• Small arresting groove at handwheel position needle bar at top
dead center
• Large arresting groove at handwheel position needle bar to bottom
dead center
3. Insert the locking peg (3) with the appropriate end into arresting
groove (1) or (2).
Removing the lock
To remove the lock:
1. Pull the locking peg (3) out of arresting groove (1) or (2).
2. Insert the plug into the locking opening (4).
26 Service Instructions 869-M PREMIUM - 00.0 - 07/2018
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Setting the handwheel scale
②③①
4 Setting the handwheel scale
Proper setting
1. Lock the machine in place at position 2 ( p. 25).
The handwheel is at position 0°.
If a different degree number is next to the marking, then you will have
to reset the graduated scale.
Fig. 15: Setting the handwheel scale
(1) - Handwheel
(2) - Washer
(3) - Marking
To set the handwheel scale:
1. Lock the machine in place ( p. 25).
2. Remove the handwheel (1).
3. Loosen and turn the washer (2).
Important
The marking (3) on the washer (2) marks the position 0°.
4. Tighten the washer (2)
5. Place the handwheel (1).
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5 Positioning the arm shaft
③
①
②
WARNING
Risk of injury from moving parts!
Crushing possible.
Switch off the machine before you check and set
the position of the arm shaft crank.
Fig. 16: Positioning the arm shaft
Positioning the arm shaft
(1) - Threaded pins
(2) - Machine casting
Proper setting
The 3 threaded pins (1) on the arm shaft crank (3) are seated completely
on the flat. The arm shaft crank (3) is flush with the machine casting (2).
To position the arm shaft:
1. Remove the arm cover ( p. 18).
2. Loosen the threaded pins (1) on the arm shaft crank (3).
3. Turn the arm shaft crank (3) such that the threaded pins (1) are seated
completely on the flat of the arm shaft.
4. Push the arm shaft (3) to the right as far as it will go and flush with
the machine casting.
5. Tighten the threaded pins (1) on the arm shaft crank (3).
(3) - Arm shaft crank
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Positioning the toothed belt wheels
6 Positioning the toothed belt wheels
Proper setting
The two toothed belt wheels must be positioned above each other so that
the toothed belt can run correctly. The winder wheel is directly next to the
upper toothed belt wheel and determines its alignment.
Important
The position of the upper toothed belt wheel is defined by the distance to
the winder wheel.
Therefore, you must first align the upper toothed belt wheel on the winder
wheel and then align the lower toothed belt wheel so that the toothed
belt runs correctly over both wheels.
WARNING
Risk of injury from moving parts!
Crushing possible.
Switch off the machine before positioning the
toothed belt wheels.
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Positioning the toothed belt wheels
③④
⑤
②
①
6.1 Positioning the upper toothed belt wheel
Fig. 17: Positioning the upper toothed belt wheel
(1) - Upper toothed belt wheel
(2) - Threaded pins
(3) - Winder wheel
Proper setting
The 2 threaded pins (2) for the upper toothed belt wheel (1) are seated
flush on the arm shaft (5).
The distance between the winder wheel (3) and the upper toothed belt
wheel (1) must be 0.8 mm.
The toothed belt (4) runs correctly without running against the retaining
ring or slipping off.
To position the upper toothed belt wheel:
1. Remove the arm cover ( p. 18).
2. Push the toothed belt (4) sufficiently far to the side so that the 2 threaded
pins (2) can be reached.
3. Loosen the threaded pins (2).
4. Turn the upper toothed belt wheel (1) so that the threaded pins(2) are
seated flush on the flat of the arm shaft (5).
5. Move the upper toothed belt wheel (1) to the side so that the distance
to the winder wheel (3) is 0.8 mm.
6. Tighten the threaded pins (2).
(4) - Toothed belt
(5) - Flat of arm shaft
7. Push the toothed belt (4) back.
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Positioning the toothed belt wheels
④
③
①
②
6.2 Positioning the lower toothed belt wheel
Fig. 18: Positioning the lower toothed belt wheel
(1) - Toothed belt
(2) - Retaining ring
Proper setting
The 2 threaded pins for the lower toothed belt wheel are seated flush on
the flat of the lower shaft.
The toothed belt (1) runs correctly without running against the retaining
ring (2) or slipping off.
To position the lower toothed belt wheel:
1. Tilt the machine head ( p. 17).
2. Loosen the threaded pins (4).
3. Turn the lower toothed belt wheel (3) such that the threaded pins (4)
are seated on the flat of the arm shaft.
4. Move the lower toothed belt wheel (3) sufficiently far to the side so that
the toothed belt (1) makes contact with the retaining ring (2) without
being pushed away.
5. Tighten the threaded pins (4).
(3) - Lower toothed belt wheel
(4) - Threaded pins
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Setting the mechanical stitch adjustment
①
7 Setting the mechanical stitch adjustment
WARNING
Risk of injury from moving parts!
Crushing possible.
Switch off the machine before you set the
mechanical stitch adjustment.
7.1 Setting the stitch regulator gear
Proper setting
The stitch regulator gear is set to 0.
No play on the stitch regulator gear. The plates for the gear are
parallel; the frame cannot be moved.
Cover
• Tilt the machine head ( p. 18)
• Remove the valve cover ( p. 20)
To set the stitch regulator gear:
1. Switch off the machine.
2. Remove the lower cover on the side.
Fig. 19: Setting the mechanical stitch adjustment (1)
(1) - Tension spring
3. Remove the tension spring (1).
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Setting the mechanical stitch adjustment
②
③④⑤
⑥
⑦
Fig. 20: Setting the mechanical stitch adjustment (2)
(2) - Frame of the stitch regulator gear
(3) - Lever
4. Loosen the screw (4).
Fig. 21: Setting the mechanical stitch adjustment (3)
(6) - Hole (7) - Recess
5. Line up the hole (6) with the recess (7).
6. Insert a locking pin (Ø 5 mm) into hole (6) and recess (7).
(4) - Screw
(5) - Plates of the stitch regulator gear
7. Manually position the plates (5) so that they are parallel.
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Setting the mechanical stitch adjustment
⑧
⑨
Fig. 22: Setting the mechanical stitch adjustment (4)
(8) - Curve (9) - Plastic track
8. Set the lever (3) so that the white plastic track (9) abuts on the control
cam (8) without play.
9. Verify that the plates (5) are still parallel to one another.
10. Tighten the screw (4).
11. Attach the tension spring (1).
Next, pull the lever with the plastic track (9) through the spring of
the stitch regulator gear and into the stop of the control cam (8).
12. Check whether the plates (5) are still parallel; if not, repeat the setting.
34 Service Instructions 869-M PREMIUM - 00.0 - 07/2018
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Setting the mechanical stitch adjustment
①
②
7.2 Setting the eccentric for the forward and backward
stitches
Proper setting
The forward and backward stitches are the same length. As a test, sew
a seam forward on a sheet of paper, stop, and sew a seam backward.
The insertions of the forward and backward stitches have to lie within one
another.
Fig. 23: Setting the eccentric for the forward and backward stitches
(1) - Eccentric (2) - Threaded pin
Proper setting
The slot of the eccentric (3) is flush with the threaded pin (1).
The values for the forward and backward stitches are calibrated at the
OP3000 control panel ( p. 129).
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Setting the feed dog
8 Setting the feed dog
WARNING
Risk of injury from moving parts!
Crushing possible.
Move the machine into the service routine before
setting the feed dog.
The position and the movement of the feed dog and needle bar have to
be coordinated such that the needle pierces exactly in the center of the
needle hole of the feed dog.
Order
First, check the following setting:
• Needle bar linkage ( p. 42)
• A straight and undamaged needle has been inserted ( Operating
Instructions)
8.1 Setting the feed dog position
Proper setting
When the stitch length is set to 0, the needle pierces exactly in the center
of the needle hole and the feed dog is exactly in the center of the throat
plate cutout, both sideways and in the sewing direction.
Information
For minimal deviations, it suffices to move the feed dog on the carrier
( p. 37).
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Setting the feed dog
① ②③ ④ ⑤
Moving the feed dog
Fig. 24: Moving the feed dog
(1) - Screw
(2) - Lever
(3) - Feed dog carrier
(4) - Stroke eccentric
(5) - Screw
To move the feed dog:
1. Execute the service routine Feed dog > PosToNeedle
( p. 14).
The software is used to define the necessary presettings on
the machine.
2. Disassemble the throat plate ( p. 22).
3. Loosen screws (1) and (5).
4. Loosen the threaded pins on the stroke eccentric (4).
5. Move the feed dog carrier (3).
Place the removed throat plate next to it as an aid for orientation so
that the feed dog can be screwed on straight.
6. Tighten screws (1) and (5).
7. Finish the service routine.
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Setting the feed dog
①
8.2 Setting the feed dog movement
The feed dog moves in an elliptical cycle. To align this correctly, the feed
movement, the stroke height, and the stroke movement of the feed dog all
have to be set.
Order
First, check the following setting:
• Feed dog position ( p. 36)
8.2.1 Setting the feed dog feed movement
Proper setting
At a handwheel position of 180°, the feed dog should stop when the
Manual bartack button (1) is pressed down at maximum stitch length.
To set the feed dog feed movement:
1. Execute the service routine Feed dog > Movement ( p. 14).
The software is used to define the necessary presettings on
the machine.
Fig. 25: Setting the feed dog feed movement (1)
(1) - Manual bartack button
2. Check if the sewing drive is at 180°.
3. If needed, use the handwheel to correct the position manually.
4. Use the Manual bartack button (1) to check if the feed dog is at a
standstill.
5. Adjust if necessary.
6. Tilt the machine head ( p. 17).
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Setting the feed dog
②
Fig. 26: Setting the feed dog feed movement (2)
(2) - Pusher eccentric
7. Loosen the threaded pins on the pusher eccentric (2).
8. Press the Manual bartack button (1) and observe the feed dog and
needle in the process.
9. Turn the pusher eccentric (2) so that feed dog and needle no longer
move when the Manual bartack button (1) is pressed.
10. Tighten the threaded pins on the pusher eccentric (2).
11. Finish the service routine.
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Setting the feed dog
②
①
③
8.2.2 Setting the feed dog height at top dead center
The feed dog reaches the maximum stroke height at top dead center.
Proper setting
Place the feed dog in the uppermost position by turning the handwheel.
The upper edge of the feed dog protrudes 0.6 - 1 mm above the
throat plate.
To set the feed dog height at top dead center:
1. Execute the service routine Feed dog > Movement
The software is used to define the necessary presettings on the
machine.
2. Turn the handwheel until the feed dog is at its highest position.
Fig. 27: Setting the feed dog height at top dead center
(1) - Free arm cover
(2) - Screw
3. Remove the free arm cover (1).
4. Loosen the screw (2).
(3) - Feed dog
( p. 14).
5. Move the feed dog (3) until it protrudes 0.6 - 1 mm from the throat plate.
6. Tighten the screw (2).
7. Finish the service routine.
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Setting the feed dog
① ③②
8.2.3 Setting the feed dog stroke movement
Order
First, check the following setting:
• Feed dog height ( p. 40)
To set the feed dog stroke movement:
1. Execute the service routine Feed dog > Movement
( p. 14).
The software is used to define the necessary presettings on
the machine.
2. Tilt the machine head ( p. 17).
Fig. 28: Setting the feed dog stroke movement
(1) - Free arm cover
(2) - Stroke eccentric
(3) - Threaded pins
3. Remove the free arm cover (1).
4. Loosen the threaded pins (3).
5. Move the handwheel into the 90° position.
6. Turn the stroke eccentric (2) such that the upper edge of the feed dog
is at the same height as the upper edge of the throat plate during the
upward movement.
7. Tighten the threaded pins (3).
8. Finish the service routine.
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Aligning the needle bar linkage
①
②
9 Aligning the needle bar linkage
WARNING
Risk of injury from moving parts!
Crushing possible.
Move the machine into the service routine before
aligning the needle bar linkage.
Order
First, check the following setting:
• A straight and undamaged needle has been inserted ( Operating
Instructions)
Proper setting
If the stitch length is 0, the needle pierces exactly in the center of the
needle hole.
9.1 Aligning the needle bar linkage sideways
Fig. 29: Aligning the needle bar linkage sideways (1)
(1) - Threaded pins (2) - Screw
To align the needle bar linkage sideways:
1. Execute the service routine Needle-Hook > Needlebar
The software is used to define the necessary presettings on
the machine.
42 Service Instructions 869-M PREMIUM - 00.0 - 07/2018
( p. 14).
Page 45
Aligning the needle bar linkage
⑥⑦
③
④
⑤
2. Remove the arm cover ( p. 18).
3. Remove the head cover ( p. 19).
4. Remove the valve cover ( p. 20).
5. Loosen the threaded pins (1) on the two adjusting rings of the shaft
for the needle bar linkage.
6. Loosen the screw (2).
Fig. 30: Aligning the needle bar linkage sideways (2)
(3) - Needle bar linkage
(4) - Throat plate
(5) - Threaded pins
7. Loosen both threaded pins (5) on the arm shaft crank (7). Make sure
that the threaded pins stay on the surface.
8. Move the needle bar linkage (3) sideways such that the needle pierces
exactly in the center of the needle hole (4) for the feed dog.
9. Push the two adjusting rings inwards as far as they will go and tighten
them, so that there is no axial play.
10. Tighten the threaded pins (1) on the two adjusting rings.
11. Tighten the screw (2).
12. Align the thread lever (6) exactly in the middle of the slot.
13. Tighten both threaded pins (5) on the arm shaft crank (7).
14. Finish the service routine.
Order
Then, check the following settings:
• Distance between hook and needle ( p. 46)
• Loop stroke position ( p. 48)
(6) - Thread lever
(7) - Arm shaft crank
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Aligning the needle bar linkage
①
②
③
126.6 mm
④
⑤
9.2 Aligning the needle bar linkage in the sewing direction
Fig. 31: Aligning the needle bar linkage in the sewing direction (1)
(1) - Arm surface
(2) - Lever
Proper setting
The lever (2) is positioned so that the distance from the arm surface (1)
to the middle of the bolt (3) is 126.6 mm.
When the stitch length is set to 0, the feed dog is positioned in the center,
and the needle pierces exactly in the center of the needle hole.
To align the needle bar linkage in the sewing direction:
1. Execute the service routine Needle-Hook > Needlebar
The software is used to define the necessary presettings on
the machine.
2. Remove the valve cover ( p. 20).
3. Tilt the machine head ( p. 17).
Fig. 32: Aligning the needle bar linkage in the sewing direction (2)
(3) - Center of bolt
( p. 14).
(4) - Threaded pins (5) - Screw
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Aligning the needle bar linkage
4. Loosen the threaded pins (4).
5. Loosen the screw (5).
6. Position the lever (2).
7. Align the needle such that it pierces exactly in the center of the
needle hole.
8. Tighten the threaded pins (4).
9. Tighten the screw (5).
10. Finish the service routine.
Order
Then, check the following settings:
• Loop stroke position ( p. 48)
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Position of the hook and needle
10 Position of the hook and needle
WARNING
Risk of injury from sharp and moving parts!
Puncture or crushing possible.
Move the machine into the service routine before
setting the position of the hook and the needle.
NOTICE
Property damage may occur!
There is a risk of machine damage, needle breakage or damage
to the thread if the distance between needle groove and hook tip is
incorrect.
Check and, if necessary, readjust the distance to the hook tip after
inserting a new needle with a different size.
10.1 Setting the hook side clearance
Order
First, check the following settings:
• A straight and undamaged needle has been inserted ( Operating
Instructions)
• Needle bar linkage is aligned correctly ( p. 42)
• Loop stroke position ( p. 48)
Proper setting
Machine is locked in place at position 1 ( p. 25).
The distance between the hook tip and the groove of the needle is
maximum 0.1 mm.
To set the hook side clearance:
1. Execute the service routine Needle-Hook > Timing
The software is used to define the necessary presettings on the
machine.
2. Tilt the machine head ( p. 17).
3. Remove the free arm cover.
4. Open the throat plate slide.
5. Disassemble the throat plate.
6. Disassemble the feed dog.
( p. 14).
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Page 49
Position of the hook and needle
②
③
④
⑤
①
Fig. 33: Setting the hook side clearance
(1) - Threaded pins
(2) - Screws
(3) - Hook support
7. Lock the machine in place at position 1 ( p. 25).
8. Loosen the threaded pins (1)
9. Loosen the screws (2).
10. Shift the hook support (3) laterally.
The distance between the hook tip (5) and the groove of the needle (4)
is maximum 0.1 mm.
The hook tip (5) does not touch the needle.
11. Tighten the screws (2).
12. Align the gear wheels relative to the hook shaft.
13. Check the loop stroke position ( p. 48).
14. Tighten the threaded pins (1).
15. Remove the lock.
16. Finish the service routine.
(4) - Needle groove
(5) - Hook tip
Order
Then, check the following settings:
17. Position of the needle guard ( p. 49)
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Page 50
10.2 Setting the loop stroke position
③
①
②
Fig. 34: Setting the loop stroke position
Position of the hook and needle
(1) - Hook tip
(2) - Vertical center line of the needle
The loop stroke is the path length from the lower dead center of the needle
bar up to the position where the hook tip is exactly on the vertical center
line of the groove for the needle.
The loop stroke is precisely 2 mm.
Order
First, check the following settings:
• Needle bar linkage is aligned correctly ( p. 42)
• A straight and undamaged needle has been inserted ( Operating
Instructions)
Proper setting
Machine is locked in place at position 1 ( p. 25).
The hook tip (1) points exactly to the vertical center line of the needle (2).
To set the loop stroke position:
1. Execute the service routine Needle-Hook > Timing
The software is used to define the necessary presettings on
the machine.
(3) - Threaded pins
( p. 14).
2. Disassemble throat plate, throat plate slide and free arm
cover ( p. 22).
3. Disassemble the feed dog ( p. 23).
4. Lock the machine in place at position 1 ( p. 25).
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Position of the hook and needle
5. Tilt the machine head ( p. 17).
6. Loosen the threaded pins (3).
7. Turn the hook such that the hook tip (1) points exactly to the vertical
center line of the needle (2).
The hook tip (1) is in the lower third of the needle groove.
8. Tighten the gear wheel.
The threaded pins (3) clamp the gear wheel.
9. Tighten the threaded pins (3).
10. Remove the lock.
11. Assemble the feed dog ( p. 23).
12. Assemble throat plate, throat plate slide and free arm cover ( p. 22).
13. Finish the service routine.
10.3 Setting the needle guard
The needle guard prevents contact between needle and hook tip.
Order
First, check the following settings:
• Loop stroke position ( p. 48)
• Hook side clearance ( p. 46)
• Needle bar height ( p. 50)
• A straight and undamaged needle has been inserted ( Operating
Instructions)
Proper setting
Machine is locked in place at position 1 ( p. 25).
The needle guard pushes the needle away just enough so that it cannot
be touched by the hook tip.
To set the needle guard:
1. Execute the service routine Needle-Hook > Timing
( p. 14).
The software is used to define the necessary presettings on
the machine.
2. Disassemble the throat plate ( p. 22).
3. Disassemble the feed dog ( p. 23).
4. Disassemble the throat plate slide ( p. 21).
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Fig. 35: Setting the needle guard
③
①
②
Position of the hook and needle
(1) - Screw
(2) - Needle guard
5. Turn the handwheel and check how far the needle guard (2) pushes
the needle away.
6. Turn the screw (1) such that the needle guard (2) just pushes the
needle (3) far away enough so that it cannot be touched by the hook tip:
• Pushing away more strongly: turn counterclockwise
• Pushing away less strongly: turn clockwise
7. Finish the service routine.
(3) - Needle
10.4 Setting the needle bar height
Order
First, check the following settings:
• Loop stroke position ( p. 48)
• A straight and undamaged needle has been inserted ( Operating
Instructions)
Proper setting
Machine is locked in place at position 1 ( p. 25).
The hook tip is level with the lower third of the groove on the needle.
Disturbance
Disturbances caused by an incorrect needle bar height
• Damage to the hook tip
• Jamming of the needle thread
• Missing stitches
• Thread breaking
• Needle breakage
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Page 53
Position of the hook and needle
①
②
③
④
Fig. 36: Setting the needle bar height
(1) - Needle bar
(2) - Screw
To set the needle bar height:
1. Execute the service routine Needle-Hook > Needlebar
The software is used to define the necessary presettings on
the machine.
2. Lock the machine in place at position 1 ( p. 25).
3. Remove the head cover ( p. 19).
4. Loosen the screw (2) of the needle bar (1).
5. Move the height of the needle bar (1) such that the hook tip (4) is in
the middle of the lower third of the groove for the needle.
When doing so, take care not to twist the needle to the side.
The groove (3) must face toward the hook.
6. Tighten the screw (2) for the needle bar (1).
7. Finish the service routine.
(3) - Needle groove
(4) - Hook tip
( p. 14).
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11 Setting the bobbin case lifter
④
③
①
②
WARNING
Risk of injury from moving parts!
Crushing possible.
Switch off the machine before setting the bobbin
case lifter.
Fig. 37: Setting the bobbin case lifter
Setting the bobbin case lifter
(1) - Bobbin case
(2) - Bobbin case lifter
The hook pulls the needle thread through between the nose of the bobbin
case (3) and the slot in the throat plate (4).
The bobbin case lifter (2) now pushes the bobbin case (1) away so that a
gap appears for the thread.
If the hook tip is located below the bobbin case lifter (2), the bobbin case
lifter (2) must open so that the thread can also slide past in that position.
So that the thread can slip through without a problem, the width of the
lifting gap and the timing of opening have to be set.
Disturbance
Disturbances caused by an incorrect setting of the bobbin case lifter:
• Thread breaking
• Formation of loops on the bottom side of the seam
• Loud machine noise
(3) - Nose of the bobbin case
(4) - Slot in the throat plate
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Setting the bobbin case lifter
②
①
③
④
Setting the lifting gap
Fig. 38: Setting the lifting gap (1)
(1) - Nose of the bobbin case (2) - Slot in the throat plate
Always check the width of the lifting gap after making changes to the
needle thread size. The correct width of the lifting gap depends on the
thickness of the needle thread.
Proper setting
The needle thread slides through unobstructed between the nose of the
bobbin case (1) and the slot in the throat plate (2).
To set the lifting gap:
1. Open the throat plate slide.
Fig. 39: Setting the lifting gap (2)
(3) - Eccentric (4) - Screw
2. Loosen the screw (4).
3. Turn the eccentric (3) so that the gap between the nose of the bobbin
case (1) and the slot in the throat plate (2) is just large enough to
allow the needle thread to slip through without a problem.
Important
Ensure that the gap is not too big. The middle part of the hook must not
swing back and forth, hitting the slot in the throat plate (2).
4. Tighten the screw (4).
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12 Sewing Feet
①② ③ ④ ⑤ ⑥
WARNING
Risk of injury from sharp and moving parts!
Puncture or crushing possible.
Move the machine into the service routine before
setting the sewing feet.
12.1 Setting the sewing foot lifting gear
Fig. 40: Setting the sewing foot lifting gear
Sewing Feet
(1) - Curve
(2) - Lever
(3) - Screw
(4) - Plates
(5) - Gear
(6) - Threaded pin
To set the lifting gear of the sewing foot:
1. Switch off the machine.
2. Remove the arm cover ( p. 18).
3. Loosen screw (3) and threaded pin (6).
4. Press the lever (2) with the roller into the stop of the control cam (1).
5. Place the plates in the gear (5) in zero position and tighten the roller
lever with screw (3).
6. Set the threaded pin (6) against the roller lever in the gear's zero
position.
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Sewing Feet
①
②
②③
①
④
12.2 Setting an even sewing foot stroke
Fig. 41: Setting an even sewing foot stroke (1)
(1) - Presser foot (2) - Feeding foot
Proper setting
For sewing foot stroke 3, the presser foot (1) and feeding foot (2) are
raised by the same height.
To set an even sewing foot stroke:
1. Execute the service routine Stroke > Equal Stroke
The software is used to define the necessary presettings on the
machine.
2. Remove the arm cover ( p. 18).
Fig. 42: Setting the sewing foot stroke (2)
(1) - Presser foot
(2) - Feeding foot
3. Loosen the screw (3).
4. Lower the feeding foot (2) to a height of 3 mm above the throat plate.
5. Tighten the screw (3).
6. Check whether the presser foot (1) and the feeding foot (2) are raised
to the same height.
If not, correct the setting.
7. Finish the service routine.
(3) - Screw
(4) - Lever
( p. 14).
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Sewing Feet
③
①
②
12.3 Setting the stroke movement for the feeding foot
Fig. 43: Setting the stroke movement for the feeding foot (1)
(1) - Feeding foot
(2) - Feed dog
Order
First, check the following settings:
• Feed dog movement ( p. 38)
• Sewing foot stroke( p. 55)
Proper setting
The feeding foot (1) touches down exactly on the feed dog (2) when the
downward movement of the needle tip (3) reaches the upper edge of the
feeding foot. This will occur when the handwheel is in the 95° position.
To set the stroke movement for the feeding foot:
1. Execute the service routine Stroke > Feed Move
The software is used to define the necessary presettings on the
machine.
2. Remove the arm cover ( p. 18).
(3) - Needle tip
( p. 14).
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Sewing Feet
⑤④
Fig. 44: Setting the stroke movement for the feeding foot (2)
(4) - Threaded pins (5) - Stroke eccentric
3. Loosen the threaded pins (4).
4. Turn the stroke eccentric (5) such that the feeding foot touches down
on the feed dog when the handwheel is in the 95° position.
Important
Ensure not to move the stroke eccentric (5) laterally on the axle.
5. Tighten the threaded pins (4).
6. Finish the service routine.
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Sewing Feet
①② ③
④
⑤⑥
12.4 Setting the sewing foot pressure and sewing foot lift
Fig. 45: Setting the sewing foot pressure and sewing foot lift
(1) - Curve
(2) - Screw
(3) - Cylinder pin 5m 6x24
(part number 9301 102221)
(4) - Guide
(5) - Setting shaft
(6) - Adjusting ring
To set the sewing foot pressure and the sewing foot lift:
1. Switch off the machine.
2. Check the machine for stiff movement in the following places:
• Guide (4)
• Setting shaft (5)
• Adjusting ring (6)
3. Eliminate stiff movement where necessary.
4. Place a 5 mm distance piece (e.g. locking pin 0367 105950) between
the presser foot and throat plate.
5. Loosen the screw (2).
6. Turn the control cam (1) to the position indicated above.
7. Peg it in place with the cylinder pin (3).
8. Tighten the screw (2).
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Sewing Feet
Sewing foot pressure
The sewing foot pressure is set via the program parameters.
The correct sewing foot pressure depends on the sewing material:
• Lower pressure for soft materials, e.g. fabric
• Higher pressure for durable materials, e.g. leather or laminate
Proper setting
The sewing material does not slip and is correctly transported.
Sewing foot lift
The sewing foot lift is set via the program parameters.
When the pedal is pressed back halfway, the sewing feet can be raised
during sewing, e. g. to move the sewing material.
When the pedal is pressed completely back, the sewing feet will be raised
after the thread is cut so that the sewing material can be removed.
Proper setting
The distance between the raised sewing feet and the throat plate is preset
to 20 mm on delivery.
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Adjusting the thread tensioning plate
③④ ⑤
⑥
①
②
13 Adjusting the thread tensioning plate
Preparing the adjustment using the Schmidt MST-2000
Use screw clamps to attach a plain sheet of metal (e.g. 6 mm aluminum)
to the tabletop on the left-hand side of the machine.
Set up the thread scale with its suction cup base on the metal plate in such
a way that the sewing thread - coming from the thread lever - lines up with
thread guides both horizontally and vertically.
Important
Use a Serafil 30 black thread to set the thread tensioning plate.
cw = turn clockwise
ccw = turn counterclockwise
13.1 Setting the machine
Fig. 46: Setting the machine
(1) - Lock screw
(2) - Thread tension spring
(3) - Stop screw
To set the machine:
1. Switch on the machine.
2. Call up the service routine Service > Settings > Thr.Tens.Top
( Service Instructions).
The software is used to define the necessary presettings on
the machine.
60 Service Instructions 869-M PREMIUM - 00.0 - 07/2018
(4) - Lock screw
(5) - Stop screw
(6) - Pre-tensioner
Page 63
Adjusting the thread tensioning plate
①
②
③④
3. Set thread tension level 2 (50%).
4. Lock the machine in place at position 1 (handwheel position 0°).
5. Remove the thread tension spring from the operating range (cw).
6. Loosen lock screws (1) and (4).
7. Loosen stop screws (3) and (5) (ccw).
8. Set the pre-tensioner (6) to a tension force of 20 cN.
Pretensioning must not significantly impair the thread tension.
13.2 Adjusting the tensioning plate
13.2.1 Adjusting the tensioning plate using the Schmidt MST-2000
Fig. 47: Adjusting the tensioning plate (1)
(1) - Lock screw
(2) - Stop screw
To adjust the tensioning plate:
1. Insert the needle thread as shown above.
Service Instructions 869-M PREMIUM - 00.0 - 07/2018 61
(3) - Stop screw
(4) - Lock screw
Page 64
Fig. 48: Adjusting the tensioning plate (2)
⑨
⑤
⑦
⑧⑥
Adjusting the thread tensioning plate
(5) - Winder
(6) - Motor ON/OFF
(7) - Display
2. Feed the needle thread through the thread lever (9) and the thread
guides of the thread scale and clamp it at the winder (5).
3. Press POWER (8) to activate the thread scale.
4. Press Motor ON/OFF (6) to start the winder (5).
5. Screw in the stop screw (2) (cw) until the tension increases, peaks and
decreases again.
The tension value is indicated on the display (7).
6. When the tension drops while you are screwing in (cw) the stopscrew (2),
set the tension to 450±10 cN (average value).
7. Secure the stop screw (2) using the lock screw (1).
Important
To prevent it from turning while it is being secured, use a 10 mm wrench
to hold the stop screw (2) in place.
8. Check the thread tension and readjust it if necessary.
9. Screw in the stop screw (3) (cw) until the tension increases, peaks and
decreases again.
The tension value is indicated on the display (7).
(8) - POWER
(9) - Thread lever
10. When the tension drops while you are screwing in (cw) the stopscrew (3),
set the tension to 720±50 cN (average value).
11. Secure the stop screw (3) using the lock screw (4).
Important
To prevent it from turning while it is being secured, use a 10 mm wrench
to hold the stop screw (3) in place.
12. Check the thread tension and readjust it if necessary.
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Adjusting the thread tensioning plate
①
②
③④
13.2.2 Adjusting the tensioning plate using a mechanical thread
scale
Fig. 49: Adjusting the tensioning plate (1)
(1) - Lock screw
(2) - Stop screw
To adjust the tensioning plate:
1. Insert the needle thread as shown above.
2. Feed the needle thread through the thread lever and the thread scale.
3. Pull the thread to the left at a consistent rate of speed.
Important
The thread must be pulled off horizontally.
4. Screw in the stop screw (2) (cw) until the tension increases, peaks and
decreases again.
5. When the tension drops while you are screwing in (cw) the stop screw (2),
set the tension to 450±10 cN.
6. Secure the stop screw (2) using the lock screw (1).
Important
To prevent it from turning while it is being secured, use a 10 mm wrench
to hold the stop screw (2) in place.
7. Check the thread tension and readjust it if necessary.
(3) - Stop screw
(4) - Lock screw
8. Screw in the stop screw (3) (cw) until the tension increases, peaks and
decreases again.
9. When the tension drops while you are screwing in (cw) the stop screw (3),
set the tension to 720±50 cN.
10. Secure the stop screw (3) using the lock screw (4).
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Adjusting the thread tensioning plate
Important
To prevent it from turning while it is being secured, use a 10 mm wrench
to hold the stop screw (3) in place.
11. Check the thread tension and readjust it if necessary.
13.3 Checking the adjusted thread tension
13.3.1 Checking the adjusted thread tension using
the Schmidt MST-2000
Fig. 50: Checking the adjusted thread tension (1)
To check the adjusted thread tension:
1. Insert the needle thread as shown above.
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Adjusting the thread tensioning plate
⑤
①
③
④②
Fig. 51: Checking the adjusted thread tension (2)
(1) - Winder
(2) - Motor ON/OFF
(3) - Display
2. Feed the needle thread through the thread lever (5) and the thread
guides of the thread scale and clamp it at the winder (1).
3. Press POWER (4) to activate the thread scale and the display (3).
4. Press Motor ON/OFF (2) to activate the motor of the thread scale.
5. Set the thread tension to level 1 (1%) at the control panel.
The thread scale should show a tension of 190±12 cN (average value).
6. Set the thread tension to level 2 (50%) at the control panel.
The thread scale should show a tension of 720±50 cN (average value).
7. Set the thread tension to level 3 (99%) at the control panel.
The thread scale should show a tension of 1600±100 cN (average
value).
Important
After completing the settings, you need to seal the magnets and the 4 nuts
that keep the magnets in place at the thread tensioning plate with sealing
wax (see figure 5).
(4) - POWER
(5) - Thread lever
8. Remove the locking peg from the machine.
9. Remove the needle thread from the thread scale.
10. Remove the thread scale.
11. Set the thread tension spring back to sewing operation (ccw,
Service Instructions, chapter Setting the thread tension spring).
12. Insert the needle thread.
13. Finish the service routine.
The machine is ready for sewing.
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Adjusting the thread tensioning plate
13.3.2 Checking the adjusted thread tension using a mechanical
thread scale
Fig. 52: Checking the adjusted thread tension (1)
To check the adjusted thread tension:
1. Insert the needle thread as shown above.
2. Feed the needle thread through the thread lever and the thread scale.
3. Pull the thread to the left at a consistent rate of speed.
Important
The thread must be pulled off horizontally.
4. Set the thread tension to level 1 (1%) at the control panel.
The thread scale should show a tension of 190±12 cN.
5. Set the thread tension to level 2 (50%) at the control panel.
The thread scale should show a tension of 720±50 cN.
6. Set the thread tension to level 3 (99%) at the control panel.
The thread scale should show a tension of 1600±100 cN.
Important
After completing the settings, you need to seal the magnets and the 4 nuts
that keep the magnets in place at the thread tensioning plate with sealing
wax (see figure 7).
7. Remove the locking peg from the machine.
8. Remove the needle thread from the thread scale.
9. Remove the thread scale.
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Adjusting the thread tensioning plate
10. Set the thread tension spring back to sewing operation (ccw, Service
Instructions, chapter Setting the thread tension spring).
11. Insert the needle thread.
12. Finish the service routine.
The machine is ready for sewing.
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Setting the needle thread tension
①
②
14 Setting the needle thread tension
CAUTION
Risk of injury from sharp and moving parts!
Puncture or crushing possible.
Switch off the machine before setting the needle
thread tension.
14.1 Setting the needle thread regulator
The needle thread regulator determines the tension applied to guide
the needle thread around the hook. The required tension depends on
the thickness of the sewing material, thread strength, and stitch length.
• Lower needle thread tension: thin sewing material, low thread
strengths
• Higher needle thread tension: thick sewing material, high thread
strengths
Proper setting
The loop of the needle thread slides at low tension over the thickest point
of the hook, without forming loops or snagging.
To set the needle thread tension:
1. Open the hook cover.
Fig. 53: Setting the needle thread regulator
(1) - Screw (2) - Needle thread regulator
2. Turn the handwheel and observe the cycle of the needle thread around
the hook.
3. Loosen the screw (1).
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Setting the needle thread tension
①
②
③
④
4. Move the needle thread regulator (2)
• Reduce needle thread tension: slide to the left
• Increase needle thread tension: slide to the right
5. Tighten the screw (1).
14.2 Setting the thread tension spring
Fig. 54: Setting the thread tension spring
(1) - Stop collar
(2) - Spring
The thread tension spring holds the needle thread under tension from
the top dead center of the thread lever up to the point when the needle eye
plunges into the sewing material.
Proper setting
The thread tension spring does not contact the stop until the needle eye
has plunged into the sewing material.
The setting for the thread tension spring must be varied according to
the sewing material and the required sewing result.
To set the thread tension spring:
1. Loosen the screw (4).
2. Turn the stop collar (1) to set the spring travel.
• Longer spring travel: turn counterclockwise
• Shorter spring travel: turn clockwise
3. Turn the tension disk (3) to set the spring tension.
• Greater spring tension: turn counterclockwise
(3) - Tension disk
(4) - Screw
• Lower spring tension: turn clockwise
Important
Do not twist the stop collar in doing so.
4. Tighten the screw (4).
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Setting the needle thread tension
14.3 Electronic needle thread tension
The electronic needle thread tension is calibrated in the factory and
cannot be changed.
If you have any inquiries about the electronic needle thread tension,
please consult Customer Service ( p. 155).
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Winder
①
②
③
④
15 Winder
WARNING
Risk of injury from moving parts!
Crushing possible.
Switch off the machine before setting the winder.
15.1 Setting the winder
Fig. 55: Setting the winder (1)
(1) - Screws
(2) - Screw
Proper setting
The winder wheel runs smoothly and without axial play.
The winding process will stop automatically when the required filling
quantity of the bobbin is reached.
To set the winder:
1. Remove the arm cover ( p. 18).
Removing the winder
2. Loosen the screws (1).
3. Remove the winder.
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(3) - Winder lever
(4) - Shank
Page 74
Winder
⑤
⑥
⑦③⑧
⑤
⑩⑥⑨
⑪
Setting the winder filling quantity
The position of the arms (4) on the winder lever (3) determines the filling
quantity:
• Parallel: Automatic winding stop at 0.5 mm below the edge of
the winder
• Closer together: Automatic stop with larger filling quantity
• Further apart from each other: Automatic stop with smaller filling
quantity
4. Turn the screw (2):
• Arms (4) closer together: turn counterclockwise
• Arms (4) further apart from each other: turn clockwise
5. Put the completely filled bobbin onto the winder.
6. Fold the winder lever (3) upwards as far as it will go to the thread.
Setting the winder spacing
Fig. 56: Setting the winder (2)
(3) - Winder lever
(5) - Thread-pulling knife
(6) - Winder spindle
(7) - Right-hand screw hole
Fig. 57: Setting the winder (3)
(8) - Block
(9) - Locking disk
(10) - Winder wheel
(11) - Marking for XXL hook
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Winder
⑫
⑧
⑩
⑬⑭ ⑮
⑭
To set the winder spacing:
7. Turn the winder spindle (6) such that the thread-pulling knife (5) is
at the top right and is facing the right-hand screw hole (7).
8. Loosen the threaded pin in the block (8).
9. Set the winder lever (3) such that the upper arm is above the marking
for the XXL hook (11).
The distance between the winder lever and the outer thread on
the bobbin is 2 – 3 mm.
10. Set the block (8) such that it is resting against the locking disk (9).
11. Set the block (8) such that its distance to the winder wheel (10)
is 0.5 mm.
12. Tighten the threaded pin in the block (8).
Setting the winder run
Fig. 58: Setting the winder (4)
(8) - Block
(10) - Winder wheel
(12) - Threaded pin
To set the winder run:
13. Loosen the threaded pin (13).
14. Set the switch cam (14) such that it is just contacting the leaf spring (15)
when the block (8) has engaged in the locking disk.
15. Set the switch cam (14) such that the winder lever (3) has no axial play.
16. Tighten the threaded pin (13).
(13) - Threaded pin
(14) - Switch cam
(15) - Leaf spring
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Assembling the winder
①
①②
Fig. 59: Setting the winder (5)
(1) - Screws
To assemble the winder:
17. Place the winder on the machine arm.
18. Tighten the screws (1).
Winder
15.2 Setting the hook thread guide
Fig. 60: Setting the hook thread guide
(1) - Screw (2) - Hook thread guide
The position of the hook thread guide determines how the hook thread is
wound onto the bobbin.
Proper setting
The hook thread is wound on evenly over the entire width of the bobbin.
To set the bobbin thread guide:
1. Loosen the screw (1).
2. Turn the hook thread guide (2):
• To the front: The hook thread will be wound on further to the front
• To the rear: The hook thread will be wound on further to the rear
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Thread cutter
A
①
②
③
16 Thread cutter
WARNING
Risk of injury from sharp and moving parts!
Cutting and crushing possible.
Switch off the machine before setting the thread
cutter.
16.1 Setting the height of the thread-pulling knife
Fig. 61: Setting the height of the thread-pulling knife
(1) - Counter blade
(2) - Thread-pulling knife
The height of the thread-pulling knife is factory-set so that the
distance between the thread-pulling knife and the middle part of the hook
is 0.3 mm.
Proper setting
The thread-pulling knife (2) pivots as closely as possible above the hook
and is at the same height as the counter blade (1).
To set the height of the thread-pulling knife:
1. Open the throat plate slide.
2. Loosen the screw (3).
3. Move the thread-pulling knife (2) in such a way that the distance
between the thread-pulling knife (2) and the middle part of the hook
is 0.3 mm.
4. Tighten the screw (3).
(3) - Screw
A – Distance
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16.2 Setting the cutoff curve
②
③
①
Fig. 62: Setting the cutoff curve (1)
Thread cutter
(1) - Screw
(2) - Control cam
Proper setting
The control cam (2) makes contact with the safety clutch.
The distance between the widest extent of the control cam (2) and
the roller (3) is no greater than 0.1 mm.
In the rest position, the thread-pulling knife should be flush with the tip
of the counter blade.
To set the cutoff curve:
1. Tilt the machine head ( p. 17).
2. Open the throat plate slide.
3. Loosen the threaded pins on the control cam (2).
4. Set the control cam (2) all the way to the right against the safety clutch.
5. Tighten the threaded pins on the control cam (2).
6. Loosen the screw (1).
7. Move the roller (3) such that the distance between the roller (3) and
the widest extent of the control cam (2) is no greater than 0.1 mm.
8. Tighten the screw (1).
(3) - Roller
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Thread cutter
⑤
⑥
④
Fig. 63: Setting the cutoff curve (2)
(4) - Threaded pins
(5) - Thread-pulling knife
9. Use the threaded pins (4) to set the thread-pulling knife (5) and the
counter blade (6) such that the tip of the thread-pulling knife (5) is flush
with the tip of the counter blade (6).
10. Loosen the threaded pins (4) and adjust the knives.
(6) - Counter blade
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16.3 Setting the cutting pressure
③
①
②
④
Fig. 64: Setting the cutting pressure
Thread cutter
(1) - Screw
(2) - Screw
The shape of the thread-pulling knife automatically creates the required
cutting pressure as soon as the thread-pulling knife and counter blade
make contact.
Proper setting
Proper cutting cannot be achieved unless the screw (1) in the free arm exerting a slight pressure - abuts on the counter blade, keeping the
counter blade from being pushed away.
Disturbance
Disturbances caused by an incorrect setting:
• Increased knife wear when the pressure is too great
• Problems when sewing on if the clamping pressure is too high
• Problems in cutting the thread
To set the cutting pressure:
1. Loosen the screw (1) before tightening it again to move it slightly against
the counter blade (4).
2. Swing out the thread-pulling knife (3) until the arrow marking points to
the cutting edge of the counter blade (4).
3. Loosen the screw (2).
(3) - Thread-pulling knife
(4) - Counter blade
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Thread cutter
③④
①
②
4. Set the thread-pulling knife (3) against the counter blade (4).
5. Tighten the screw (2).
16.4 Setting point in time for cutting
Fig. 65: Setting point in time for cutting
(1) - Roller
(2) - Control cam
Proper setting
The threads are cut when the thread lever is at the top dead center (handwheel position 60°).
To set the point in time for cutting:
1. Tilt the machine head ( p. 17).
2. Open the throat plate slide.
3. Loosen the threaded pins on the control cam (2).
4. Move the thread-pulling knife (4) to its initial position.
5. Set the handwheel position to 60°.
6. Turn the control cam (2) such that the roller (1) runs up at the contour
of control cam (2) and the widest extent of the control cam (2) is at
handwheel position 60° at the highest point.
7. Tighten the threaded pins on the control cam (2).
8. Check setting:
• Insert the thread into thread-pulling knife (4) and slowly turn the
handwheel.
(3) - Counter blade
(4) - Thread-pulling knife
• Check the handwheel position at which the thread is cut.
9. If necessary, repeat setting steps 1 – 7 until the cut takes place at 60°.
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Setting the safety snap-on coupling
①
②③
17 Setting the safety snap-on coupling
The safety snap-on coupling disengages in the event of the thread
jamming and thus prevents the hook from being misadjusted or damaged.
17.1 Attaching the safety snap-on coupling
Fig. 66: Attaching the safety snap-on coupling
(1) - Threaded pins
(2) - Left-hand adjusting ring
Proper setting
The 4 threaded pins (1) on the two adjusting rings next to the safety snapon coupling (3) must be parallel to one another. After the safety snap-on
coupling has disengaged, they are no longer parallel.
To latch the safety snap-on coupling:
1. Tilt the machine head ( p. 17).
2. Turn the left adjusting ring (2) such that the threaded pins (1) are
parallel to one another.
The safety snap-on coupling latches into place.
(3) - Safety snap-on coupling
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Page 83
Setting the safety snap-on coupling
①
②③ ④
⑤
⑥
⑦
17.2 Setting the torque
NOTICE
Property damage may occur!
If you change the torque, it could be that the coupling will not
disengage although this would be required.
This could cause machine damage, e.g. in the event of the thread
jamming.
Do NOT change the factory setting.
Make sure that the torque remains at 8 Nm.
Fig. 67: Setting the torque
(1) - Threaded pins
(2) - Left-hand adjusting ring
(3) - Safety snap-on coupling
(4) - Right-hand adjusting ring
Proper setting
The machine is set at the factory so that the torque is 8 Nm when
the marking point (6) is exactly above the setting slot (5) of the disk.
To set the torque:
1. Tilt the machine head ( p. 17).
2. Loosen the screw (7).
3. Using the screwdriver, turn the disk on the setting slot (5) so that 8 Nm
is reached for the torque:
• Increase force: turn in the direction +
• Decrease force: turn in the direction -
4. Tighten the screw (7).
(5) - Setting slot
(6) - Marking point
(7) - Screw
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18 Integrated motor
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DANGER
Risk of injury from electricity!
Unprotected contact with electricity can result in
serious injuries or death.
Work on the electrical system must ONLY be
carried out by qualified electricians or appropriately
trained and authorized personnel.
ALWAYS pull the power plug before working on the
electrical equipment.
WARNING
Risk of injury from moving parts!
Crushing possible.
Integrated motor
The machine may only be disassembled and
assembled by trained specialists.
18.1 Overview of the components
Fig. 68: Overview of the components
(1) - Handwheel
(2) - Handwheel flange
(3) - Encoder
(4) - Encoder disk
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(5) - Cover plate
(6) - Stator
(7) - Ring
(8) - Rotor
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Integrated motor
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18.2 Disassembling the drive
18.2.1 Disassembling the handwheel and handwheel flange
Fig. 69: Disassembling the handwheel and handwheel flange
(1) - Handwheel
(2) - Screws
To disassemble the handwheel and handwheel flange:
1. Loosen all 3 screws (2) on the handwheel (1).
2. Loosen all threaded pins (3) and remove the handwheel flange (4).
18.2.2 Removing the cover
Fig. 70: Removing the cover
(3) - Threaded pins
(4) - Handwheel flange
(1) - Screws
(2) - Cover
To remove the cover:
1. Loosen all 5 screws (1).
2. Remove the cover (2) from the side.
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(3) - Handwheel flange
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18.2.3 Disassembling the encoder
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Fig. 71: Disassembling the encoder
Integrated motor
(1) - Encoder disk
(2) - Encoder
To disassemble the encoder:
1. Unscrew the retaining plate (3).
2. Loosen both screws on the encoder (2).
3. Undo the screw on the encoder disk (1).
4. Carefully and uniformly pull the encoder (2) and encoder disk (1) away
from the shaft.
18.2.4 Disassembling the stator
Fig. 72: Disassembling the stator
(3) - Retaining plate
(1) - Stator with ring
(2) - Screws
To disassemble the stator:
1. Loosen the screws (2).
2. Remove the cover plate (3).
3. Remove the stator with ring (1).
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(3) - Cover plate
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18.2.5 Disassembling the rotor
Fig. 73: Disassembling the rotor
(1) - Threaded pins
(2) - Threaded pins
(3) - Rotor with deep groove ball bearing
To disassemble the rotor:
1. Remove the arm cover ( p. 18).
2. Loosen the threaded pins (1), (2).
3. Remove the rotor with deep groove ball bearing (3).
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18.3 Assembling the drive
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18.3.1 Assembling the rotor
Fig. 74: Assembling the rotor
Integrated motor
(1) - Threaded pins
(2) - Threaded pins
(3) - Rotor with deep groove ball bearing
To assemble the rotor:
1. Push the rotor with deep groove ball bearing (3) onto the shaft until
the deep groove ball bearing is resting against the stop.
2. Screw all threaded pins (1), (2) firmly in place, observing the surface
of the shaft in doing so: Screw the first screw in the direction of rotation
firmly in place on the surface.
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18.3.2 Assembling the stator
NOTICE
Property damage may occur!
The stator can be attracted by applying magnetic force.
Work carefully and in a controlled manner.
Fig. 75: Assembling the stator
(1) - Stator with ring
(2) - Screws
To assemble the stator:
1. Push the stator with ring (1) onto the shaft, paying attention to the ring
gap for the cable.
2. Assemble the cover plate (3).
3. Evenly screw the screws (2) firmly in place so that a uniform gap exists
between the cover plate (3) and shaft.
(3) - Cover plate
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18.3.3 Assembling the encoder
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Fig. 76: Assembling the encoder
Integrated motor
(1) - Encoder disk
(2) - Encoder
To fit the encoder:
1. Push the encoder (2) and encoder disk (1) onto the shaft.
2. Align the encoder disk (1) so that it runs in the middle of the encoder (2).
3. Screw the encoder disk (1) and encoder (2) firmly in place.
4. Tighten the retaining plate (3).
18.3.4 Assembling the cover
Fig. 77: Assembling the cover
(3) - Retaining plate
(1) - Screws (2) - Cover
To place the cover:
1. Position the cover (2) at the side.
2. Tighten the screws (1).
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18.3.5 Locking the machine in place
Fig. 78: Locking the machine in place
(1) - Locking peg
To lock the machine in place:
1. Lock the machine in place using the locking peg (1) (Ø 3 mm).
The needle is in the top dead center position.
18.3.6 Assembling the handwheel flange
Fig. 79: Assembling the handwheel flange
o
(1) - Handwheel flange marking
(2) - Cover marking
(3) - Threaded pins
(4) - Handwheel flange
To assemble the handwheel flange:
1. Attach the handwheel flange (4) so that the two markings (1), (2) are
in line.
2. Screw both threaded pins (3) firmly in place.
In doing so, make sure that there is a distance of approx. 0.5 - 1 mm
between the handwheel flange (4) and the cover plate.
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18.3.7 Assembling the handwheel
Fig. 80: Assembling the handwheel
(1) - Handwheel (2) - Screws
To assemble the handwheel:
1. Attach the handwheel (1) and tighten all 3 screws (2).
2. Set the reference position via the control; see Instructions for
use DAC comfort.
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Programming
4.0 25 5 3.0
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19 Programming
This chapter deals exclusively with content on the Technician level. For a
description of how to create programs or how to make changes to the
sewing parameters, the programming on the Operator level is explained
in the Operating Instructions 869-M PREMIUM.
19.1 Calling up the Technician level
A password is requested to make it possible to make changes on the
Technician level.
To access the Technician level:
1. Switch on the machine.
2. Press the P and S buttons at the same time.
The display shows the input screen for the password:
Fig. 81: Password input screen
Code
1.9
3. Use the numeric buttons to enter the password (25483).
You are on the Technician level:
19.2 Structure of the software
After the Technician level opens, the display shows the menu items for the
protected area. The following table lists the menu items and gives a brief
explanation.
Submenu Description Reference
Lock Techn. Lock the Technician level p. 92
ParameterCall Parameter selection
(visible only when activated)
Default Program Program presettings p. 94
51
p. 92
Machine config. Machine configuration p. 97
User config. User configuration p. 111
Service Service p. 124
Counter Counter p. 131
Reset Reset data p. 131
Data transfer Data transfer p. 132
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Programming
A further branching into the submenus cannot be shown here for reasons
of space. A corresponding overview of the menu items appears at the
beginning of each chapter.
19.3 Lock technician level (Lock Techn.) submenu
There are two options to exit the Technician level: the first one will allow you
to access the Technician level again without re-entering your password
while the other will result in a prompt to enter your password for re-gaining
access to the Technician level.
Secure option to exit the Technician level
1. Select the Lock Techn. parameter.
2. Press the OK button to confirm the parameter.
You are on the Technician level. After pressing the buttons P and S,
you will not be able to access the Technician level unless you
re-enter your password.
Non-secure option to exit the Technician level
1. Exit the Technician level with a press of the
You are on the Technician level. You can access the Technician level
by pressing the buttons P and S without the need to enter your password again.
Information
If accessing the Technician level by means of a USB key, you will exit the
Technician level automatically when removing the USB key.
◄ button or the ESC button.
19.4 ParameterCall submenu
The submenu is visible only if the
ParameterView parameter ( p. 112) is active. The settings for a
parameter can be changed directly here.
To change the parameters:
1. Select the menu item Service > ParameterCall.
2. Press the OK button to confirm the selection.
A window appears where the parameter can be selected:
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Programming
+
Kat Par Mode
Lvl
Fig. 82: ParameterCall submenu
Param. aufrufen
T
01 00 6
3. Select the level of the desired parameter with the ▲/▼ buttons.
Abbreviation Meaning
O Operator/user
T Technician
4. Use the
value with the
► button to move to the Cat category and select the desired
▲/▼ buttons or the numeric buttons. The categories are
explained in the Parameter list 869-M PREMIUM.
5. Use the
value with the
► button to move to the Par parameter and select the desired
▲/▼ buttons or the number keys. The parameters are
explained in the Parameter list 869-M PREMIUM.
6. Use the
► button to move to the fourth value on the far right. This value
may vary, depending on the parameter. It may be a mode or a window
with an action selection.
7. Enter parameter value and confirm by pressing OK.
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19.5 Default Program submenu
Customer-specific settings can be made here, which are automatically
used as preset values for the first seam section during the creation of a
new program. Select the values so that they can be retained for as many
programs as possible.
The menu is divided into the following submenus:
Parameter Explanation Reference
Stitch length Stitch length p. 94
Foot Press. Foot Press. p. 95
Thr.Tens. Needle thread tension p. 95
Foot Stroke Sewing foot stroke p. 95
Start bartack Start bartack p. 96
End bartack End bartack p. 96
Thread Trim Thread cutter p. 96
DailyPieces Daily pieces counter p. 96
19.5.1 Setting the Stitch length (Stitchlen.) parameter
NOTICE
Property damage may occur!
The machine and the sewing equipment may be damaged.
ALWAYS adjust the stitch length to the selected sewing equipment.
Stitch length that should be set as standard when creating a new program.
To set the stitch length parameter:
1. Select the Stitchlen. parameter.
2. Press the OK button to confirm the selection.
3. Enter the desired value.
4. Press the OK button to confirm the value.
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19.5.2 Setting the Foot pressure (Foot Press.) parameter
Foot pressure that should be set as standard when creating a new program.
To set the Foot pressure parameter:
1. Select the Foot Press. parameter.
2. Press the OK button to confirm the selection.
3. Enter the desired value (01 – 20).
4. Press the OK button to confirm the value.
19.5.3 Setting the Needle thread tension (Thr.Tens.) parameter
Needle thread tension that should be set as standard when creating a new
program.
To set the Needle thread tension parameter:
1. Select the Thr.Tens. parameter.
2. Press the OK button to confirm the selection.
3. Enter the desired value (01 – 99 %).
4. Press the OK button to confirm the value.
Information
The menu is expanded for 2-needle machines. It is then possible to set
the needle thread tension for the right and left sides.
19.5.4 Setting the Sewing foot stroke (Foot Stroke) parameter
Sewing foot stroke that should be set as standard when creating a new
program.
To set the Sewing foot stroke parameter:
1. Select the Foot Stroke parameter.
2. Press the OK button to confirm the selection.
3. Enter the desired value (0.5 – 9.0).
4. Press the OK button to confirm the value.
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Programming
19.5.5 Setting the Start bartack (Start Tack) parameter
Setting whether the start bartack is automatically activated in a new
program.
Menu item Setting option
On The start bartack is activated automatically. The values for the start
bartack are taken from the Manual mode.
Off The start bartack is not activated.
19.5.6 Setting the End bartack (End Tack) parameter
Setting whether the end bartack is automatically activated in a new
program.
Menu item Setting option
On The end bartack is activated automatically. The values for the end
bartack are taken from the Manual mode.
Off The end bartack is not activated.
19.5.7 Setting the Thread cutter (Thread Trim) parameter
Setting whether the thread cutter is automatically activated in a new
program or not.
Menu item Setting option
On The thread cutter is activated automatically at the end of a seam
section and at the end of the sewing program.
Off The thread cutter is not activated.
19.5.8 Setting the Daily pieces counter (DailyPieces) parameter
The daily pieces counter can count upward or downward. It is also possible
to enter the value to be selected when the counter is reset.
Menu item Setting option
CntMode Off – the counter is off
Up – the daily pieces counter counts upward
Down – the daily pieces counter counts downward
Reset Enter the value to which the daily pieces counter should return when it
is reset (value range -999 - 999).
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19.6 Machine config. submenu
Settings on the machine that apply to all programs can be made here.
The parameters are explained in more detail in the subchapters.
The menu is divided into the following submenus:
Parameter Explanation Reference
Thread Trim Thread cutter p. 98
Thread clamp Thread clamp p. 99
Speed Speed p. 101
Stop Positions Stop positions p. 101
Foot Sewing foot p. 102
Thr.Tens. Needle thread tension p. 102
Stroke Sewing foot stroke p. 103
Stitch length Stitch length p. 104
Bobbin Bobbin p. 104
Holding Force Motor holding force p. 104
Pedal Pedal p. 106
Needle cooling Needle cooling p. 106
Center Guide Seam middle guide p. 107
Puller Puller p. 107
EdgeGuide Edge guide p. 109
Mat.Thickness Material thickness detection p. 109
Speed Corr Correcting effects of high speed p. 110
Light barrier Light barrier p. 110
Mode Seg.Size Segment length p. 111
Threading Threading mode p. 111
Operation lock Operation lock p. 111
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19.6.1 Setting the Thread cutter (Thread Trim) parameter
Various settings can be made for the thread cutter. The possibilities are
explained in more detail in the table.
Menu item Setting option
On/Off The thread cutter can generally be activated or deactivated; if it is
deactivated here, it can no longer be selected on the operator
level.
Speed Speed of the machine during thread cutting.
(Value range 050 – 250 [rpm])
Start Trim Position when the magnet of the thread cutter is activated.
(Value range 000 – 359)
Stop Trim Position when the magnet of the thread cutter is deactivated.
(Value range 000 – 359)
StopBottom° Needle position at bottom dead center during the seam, specified
in degrees.
(Value range 000 – 359)
After Trim Needle position after thread cutting before reversal.
(Value range 000 – 359)
Turn Back Reversal after cutting the thread is active or inactive.
(Value range: On/Off)
StopIdle° Position of the needle after thread cutting (reversal position); the
needle is set upward to reach the full lifting height, and the thread
lever is then no longer at top dead center.
(Value range 000 – 359)
Tens.Open Needle position at which the needle thread tension switches to the
value for thread cutting (Thr.Tens).
(Value range 000 – 359)
Tens.Close Position at which the standard needle thread tension is used again
after thread cutting.
(Value range 000 – 359)
Thr.Tens. Needle thread tension during thread cutting.
(Value range 00 – 50 [%])
t TensClose Delay, showing how long it takes until the standard needle thread
tension is used again.
(Value range 000 – 200 [ms])
Short Stitch Start St.
Number of short stitches at the seam start; advisable for neat
starts to sewing.
(Value range 00 – 99)
End St.
Number of short stitches at the seam end, to ensure that the
length difference between the needle thread and the hook thread
is (visually) as small as possible.
(Value range 00 – 99)
St.Length
Stitch length of the short stitches, generally between
01.0–01.5[mm].
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