DURKOPP ADLER 869-M Premium Service Instructions Manual Download

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Positioning the toothed belt wheels

Service Instructions 869-M PREMIUM - 00.0 - 07/2018

6.1 Positioning the upper toothed belt wheel

Fig. 17: Positioning the upper toothed belt 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).
7. Push the toothed belt (4) back.

(1)

- Upper toothed belt wheel

(2)

- Threaded pins

(3)

- Winder wheel

(4)

- Toothed belt

(5)

- Flat of arm shaft

③

④

⑤

②

①

Summary of Contents for 869-M Premium

Page 1: ...869 M PREMIUM Service Instructions...

Page 2: ...er AG and protected by copyright Any reuse of these contents including extracts is prohibited without the prior written approval of D rkopp Adler AG Copyright D rkopp Adler AG 2018 IMPORTANT READ CARE...

Page 3: ...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 upp...

Page 4: ...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 th...

Page 5: ...ot 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 1...

Page 6: ...ubmenu 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...

Page 7: ...propriate technical training for performing maintenance or repairing malfunctions With regard to minimum qualification and other requirements to be met by personnel please also follow the chapter Safe...

Page 8: ...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 instruc...

Page 9: ...tandards and regulations D rkopp Adler cannot be held liable for any damage resulting from Breakage and damage during transport Failure to observe these instructions Improper use Unauthorized modifica...

Page 10: ...About these instructions 8 Service Instructions 869 M PREMIUM 00 0 07 2018...

Page 11: ...rts 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 secur...

Page 12: ...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 word...

Page 13: ...ven fatal injury if ignored This is what a warning looks like for a hazard that could result in moderate or minor injury if the warning is ignored Puncture Crushing Environmental damage Symbol Type of...

Page 14: ...n envi ronmental damage if ignored This is what a warning looks like for a hazard that could result in property damage if ignored CAUTION Type and source of danger Consequences of non compliance Measu...

Page 15: ...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 loop...

Page 16: ...ne 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 serv...

Page 17: ...on lights up The display shows the information that the Service Stop is active Fig 3 Calling up the service routine 3 8 Make the required settings 9 Press the Service Stop button The power is switched...

Page 18: ...ble 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 WARNING Risk of injury from moving parts Crushing...

Page 19: ...e head Fig 5 Tilting the machine head 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...

Page 20: ...ng and placing the arm cover Fig 6 Removing and placing the arm cover Removing the arm cover To remove the arm cover 1 Loosen the screws 2 2 Remove the arm cover 1 Placing the arm cover To place the a...

Page 21: ...nd placing the head cover Fig 7 Removing and placing the head cover 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...

Page 22: ...ing the valve cover 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 val...

Page 23: ...ssembling and assembling the throat plate slide 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...

Page 24: ...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 pl...

Page 25: ...te 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...

Page 26: ...nt 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 Fla...

Page 27: ...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 arr...

Page 28: ...mall 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...

Page 29: ...ion 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 To set the handwheel scale 1 Lock the machine in place p 25...

Page 30: ...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 s...

Page 31: ...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...

Page 32: ...thout running against the retaining ring or slipping off To position the upper toothed belt wheel 1 Remove the arm cover p 18 2 Pushthetoothedbelt 4 sufficientlyfartothesidesothatthe2threaded pins 2 c...

Page 33: ...ithout 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 suc...

Page 34: ...tor 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...

Page 35: ...ment 2 4 Loosen the screw 4 Fig 21 Setting the mechanical stitch adjustment 3 5 Line up the hole 6 with the recess 7 6 Insert a locking pin 5 mm into hole 6 and recess 7 7 Manually position the plates...

Page 36: ...k 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 trac...

Page 37: ...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 forw...

Page 38: ...ht 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 nee...

Page 39: ...efine 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...

Page 40: ...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 d...

Page 41: ...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...

Page 42: ...above the throat plate To set the feed dog height at top dead center 1 Execute the service routine Feed dog Movement p 14 The software is used to define the necessary presettings on the machine 2 Tur...

Page 43: ...efine the necessary presettings on the machine 2 Tilt the machine head p 17 Fig 28 Setting the feed dog stroke movement 3 Remove the free arm cover 1 4 Loosen the threaded pins 3 5 Move the handwheel...

Page 44: ...e 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 To align the needle bar linkage sideways 1 Execute the...

Page 45: ...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 the...

Page 46: ...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 directio...

Page 47: ...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...

Page 48: ...the service routine Needle Hook Timing p 14 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 sl...

Page 49: ...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 1...

Page 50: ...eedle 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...

Page 51: ...h 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...

Page 52: ...Pushing away less strongly turn clockwise 7 Finish the service routine 10 4 Setting the needle bar height Order First check the following settings Loop stroke position p 48 A straight and undamaged n...

Page 53: ...achine 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 mid...

Page 54: ...n 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 ti...

Page 55: ...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 2 Loosen the screw 4 3 Turn the eccentric 3 so that the gap...

Page 56: ...w 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 thre...

Page 57: ...ce routine Stroke Equal Stroke p 14 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 3 Loosen the screw 3 4 L...

Page 58: ...5 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...

Page 59: ...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 eccen...

Page 60: ...chine 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 t...

Page 61: ...roper 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 f...

Page 62: ...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 tu...

Page 63: ...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 t...

Page 64: ...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 thr...

Page 65: ...in the stop screw 2 cw until the tension increases peaks and decreases again 5 Whenthetensiondropswhileyouarescrewingin cw thestopscrew 2 set the tension to 450 10 cN 6 Secure the stop screw 2 using t...

Page 66: ...d 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 us...

Page 67: ...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...

Page 68: ...lled 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 thr...

Page 69: ...ctions 869 M PREMIUM 00 0 07 2018 67 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...

Page 70: ...ial 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...

Page 71: ...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...

Page 72: ...69 M PREMIUM 00 0 07 2018 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 n...

Page 73: ...out 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 sc...

Page 74: ...rom 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 fil...

Page 75: ...obbin 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 bloc...

Page 76: ...ook 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...

Page 77: ...lling 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 scr...

Page 78: ...ead 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...

Page 79: ...curve 2 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 t...

Page 80: ...ht 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 Prob...

Page 81: ...e 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...

Page 82: ...hing the safety snap on coupling Proper setting The 4 threaded pins 1 on the two adjusting rings next to the safety snap on coupling 3 must be parallel to one another After the safety snap on coupling...

Page 83: ...e 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 NOTICE Property damage may occur If...

Page 84: ...us 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...

Page 85: ...ndwheel flange 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...

Page 86: ...h 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 Disassemblin...

Page 87: ...18 2 5 Disassembling the rotor Fig 73 Disassembling the rotor 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 1...

Page 88: ...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 th...

Page 89: ...g 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 sh...

Page 90: ...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 Assembl...

Page 91: ...center position 18 3 6 Assembling the handwheel flange Fig 79 Assembling the handwheel flange To assemble the handwheel flange 1 Attach the handwheel flange 4 so that the two markings 1 2 are in line...

Page 92: ...0 0 07 2018 18 3 7 Assembling the handwheel Fig 80 Assembling the handwheel To assemble the handwheel 1 Attach the handwheel 1 and tighten all 3 screws 2 2 Set the reference position via the control s...

Page 93: ...time The display shows the input screen for the password Fig 81 Password input screen 3 Use the numeric buttons to enter the password 25483 You are on the Technician level 19 2 Structure of the softwa...

Page 94: ...hnician 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 Technic...

Page 95: ...meter list 869 M PREMIUM 5 Use the button to move to the Par parameter and select the desired value with the buttons or the number keys The parameters are explained in the Parameter list 869 M PREMIUM...

Page 96: ...tandard 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 t...

Page 97: ...en 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 butto...

Page 98: ...to be selected when the counter is reset 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...

Page 99: ...ositions 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 hold...

Page 100: ...e 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...

Page 101: ...tivation duration of the thread cutter in time period t1 Value range 000 1000 ms DtyC t1 Duty cycle in time period t1 Value range 000 1000 t2 s Activation duration of the thread cutter in time period...

Page 102: ...lue range 000 1000 t2 s Activation duration of thread clamp in time period t2 Value range 000 1000 ms DtyC t2 Duty cycle in time period t2 Value range 000 1000 NSB Neat Seam Beginning Value range On O...

Page 103: ...sible at operator level Value range 050 400 rpm Pos Speed Position speed the last stitch is made slower during stopping of the sewing procedure Value range 010 700 rpm Soft Speed Speed for the soft st...

Page 104: ...lifted Value range 01 60 Menu item Setting options FL Tens Mode Mode for lifting the needle thread tension during active sewing foot lift 0 Needle thread tension is not lifted 1 The needle thread ten...

Page 105: ...the case of material thickness detection Value range On Off StitchOff Number of stitches after which the second sewing foot stroke is automatically deactivated Value range 000 255 Automatic Speed Spe...

Page 106: ...this will vary depend ing on the sewing equipment and MUST be adjusted when changing the sewing equipment When the value is changed the machine requests a reset i e switching off and on again Cf p 23...

Page 107: ...ation the machine will indicate an error message during the seam which must be confirmed with OK The error disappears If the parameter MsgAfterTrim is active the error will be displayed again after th...

Page 108: ...Number of speed steps processed by the pedal Value range 00 64 Curve Speed curve of the pedal t Posit 1 Debouncing of position 1 Value range 000 255 ms t Posit 2 Debouncing of position 2 Value range 0...

Page 109: ...en sewing the bartack OnLift Raising of the seam center guide when lifting the sewing foot Tack Lift Raising of the seam center guide when sewing the bartack and lifting the sewing foot RaiseOnHP When...

Page 110: ...gulated via the gage at the puller HPNo Pressure is generated actively except for the 2nd stroke height No No active pressure from puller SwitchOff Puller is not active when the sewing motor is stoppe...

Page 111: ...500 60000 Hz Min gap Smallest possible gap between the sewing foot and the edge guide This will vary depending on the sewing equipment and MUST be adjusted when changing the sewing equipment CAUTION T...

Page 112: ...is no constant alternating between activation and deactivation in the boundary range Value range 0 0 2 0 mm Menu item Setting options On Off Light barrier active inactive Speed The last stitches afte...

Page 113: ...ake working on the machine in various external conditions easier for the user The parameters are explained in more detail in the subchapters The menu is divided into the following submenus Menu item S...

Page 114: ...parameter numbers can be activated or deactivated When activated the parameter numbers appear on the display on the left next to the menu items Fig 83 Example ParameterView inactive Output Config Con...

Page 115: ...puts here The table shows the inputs and their allocation Machine input signal Input Buttons on the button bar S1 X120T 3 S2 X120T 16 S3 X120T 4 S4 X120T 17 S5 X120T 5 S6 X120T 18 Knee button S1 X120T...

Page 116: ...stitch 6 Point position 8 Needle height 11 2 Needle thread tension 12 Change of stitch length 15 Seam center guide puller 18 Light barrier 20 Operation lock when contact is opened normally NO 21 Quick...

Page 117: ...eter T 56 00 The following table lists the modes Machine output signal Output ML X22 X120B 9 NK X22 X120B 10 RA X16 X120B 12 STL X17 X120B 22 STL FA X18 X120B 23 FL X15 X22 X90 12 FF3 OUT X22 X90 15 M...

Page 118: ...the inputs outputs can be assigned using the parameters T 53 00 p 113 and T 56 00 p 115 See below for wiring examples of the additional inputs outputs Fig 85 Connection of the additional inputs output...

Page 119: ...mfort X80B 1 24V 2 IN1 3 IN3 4 IN5 5 IN7 6 7 8 24V 9 OUT1 10 OUT3 11 OUT5 12 OUT7 13 GND GND 14 IN2 15 IN4 16 IN6 17 IN8 18 GND 19 20 24V 21 OUT2 22 OUT4 23 OUT6 24 OUT8 25 X80T 1 24V 2 IN9 3 IN11 4 I...

Page 120: ...Programming 118 Service Instructions 869 M PREMIUM 00 0 07 2018 Fig 89 Connecting adapter to DACcomfort...

Page 121: ...terfaces can be used for the barcode scanner The parameter is active if a barcode scanner is connected It is possible to define additional settings for the operation lock The possibilities are explain...

Page 122: ...on the pedal Value range On Off Notice Position 2 actually causes a cancelation when actuated during a seam section If the section change function is assigned to Position 2 the softkey menu can be us...

Page 123: ...nly USB Access via USB key with access file only USB Code Access via defined password or USB key with access file Security Key The defined password is saved as a file to a USB key The USB key provides...

Page 124: ...hat may have been selected for the info screen are displayed Program Selective restriction of access to the existing program and its parameters R W Read Write Off Area is hidden R O Read Only Programm...

Page 125: ...Enter the desired value 010 255 4 Press the OK button to confirm the value 19 7 15 Setting the Brightness Brightness parameter Set the brightness of the OP3000 to the user s needs here To set the par...

Page 126: ...ts according to the wiring diagram To test the outputs 1 Select the desired output with the buttons Fig 90 Test Output subitem Parameter Explanation Reference Multitest Multitest p 124 Settings Servic...

Page 127: ...91 Test PWM subitem 2 Press the OK button to confirm the selection The Value display toggles between On and Off every time the OK button is pressed 3 Observe the selected element and check if a press...

Page 128: ...beforehand via the display To perform the test steps 1 Confirm the element In Input the display shows the number of the element last changed If the element is functional the display switches between...

Page 129: ...tons to test the selected motor If the motor is functioning correctly the behavior described in the table will be shown Information There is no specific procedure for testing the stepper motor encoder...

Page 130: ...ely to the area of the mechanics Details on that area can be found in the Service routine chapter p 14 19 8 3 Setting the Calibration Calibration parameter Various parameters need to be calibrated the...

Page 131: ...and check the stitch length 7 If the test run is the correct length confirm with the OK button After calibrating the stitch length it is advisable to perform another test in standard sewing mode Sele...

Page 132: ...atch the forward stitch length To calibrate the stitch adjustment lever 1 Call up the Service Calibration Man St Len menu item 2 Value for the potentiometer should match the proposed value of 2500 3 A...

Page 133: ...set submenu Use this submenu to reset the data of the machine Various settings can be made for resetting the data The possibilities are explained in more detail in the table Access is possible only by...

Page 134: ...menu Use this submenu to transfer data between the machine or more precisely the control and a USB key Various options are available for the data transfer which are explained in the subchapters The me...

Page 135: ...menu 2 Call up the Service Data Transfer All Data menu item 3 Press the OK button to confirm the selection 4 Use the buttons to choose between the options Load from USB or Store to USB 5 Press the OK...

Page 136: ...key or the control To transfer the parameter settings and calibration values 1 Plug the USB key into the socket 1 on the control 2 Fig 101 Data Transfer submenu 2 Call up the Service Data Transfer On...

Page 137: ...ating that the USB key must not be removed Fig 103 USB key warning The message disappears after the data transfer 19 11 3 Setting the Programs Programs parameter It is possible to transfer all or just...

Page 138: ...warning message appears Fig 105 Data loss warning message 6 Select a program with the buttons 7 Press the OK button to confirm the selection A check mark in front of the program name shows that it has...

Page 139: ...ng that the USB key must not be removed Fig 106 USB key warning The message disappears after the data transfer 19 11 4 Saving the Error list Error Log parameter The error list can be saved to a USB ke...

Page 140: ...3 of the control panel on the left Fig 108 Performing a software update As soon as the software update is finished the display will also show the software version 4 of the machine on the right Fig 10...

Page 141: ...Programming Service Instructions 869 M PREMIUM 00 0 07 2018 139 5 Remove the USB key from the control The software update is complete and the machine is ready to sew...

Page 142: ...Programming 140 Service Instructions 869 M PREMIUM 00 0 07 2018...

Page 143: ...maintenance work switch off the machine or set the machine to threading mode WARNING Risk of injury from moving parts Crushing possible Prior to any maintenance work switch off the machine or set the...

Page 144: ...particles can enter the eyes causing injury Wear safety goggles Hold the compressed air gun so that the particles do not fly close to people Make sure no particles fly into the oil pan NOTICE Propert...

Page 145: ...10 or oil of equivalent quality with the following specifications Viscosity at 40 C 10 mm s Flash point 150 C CAUTION Risk of injury from contact with oil Oil can cause a rash if it comes into contact...

Page 146: ...raise above the MAX marking 2 or drop below the MIN marking 3 If the oil level falls below the minimum level marking 3 the oil level indicator lights up in red To top off the oil 1 Fill oil through th...

Page 147: ...g Proper setting After sewing a stretch of approx 1 m the blotting paper will have been sprayed with a thin and even film of oil To set the hook lubrication 1 Turn the screw 1 Release more oil turn co...

Page 148: ...sis Fig 113 Setting the operating pressure To set the operating pressure 1 Pull the pressure controller 1 up 2 Turn the pressure controller until the pressure gage 2 indicates the proper setting Incre...

Page 149: ...2 on a daily basis Fig 114 Draining the water condensation To drain water condensation 1 Disconnect the machine from the compressed air supply 2 Place the collection tray under the drain screw 3 3 Loo...

Page 150: ...Loosen the filter element 1 5 Blow out the filter element 1 using the compressed air gun 6 Wash out the filter tray using benzine 7 Tighten the filter element 1 8 Tighten the water separator 2 9 Tigh...

Page 151: ...Maintenance Service Instructions 869 M PREMIUM 00 0 07 2018 149 20 4 Parts list A parts list can be ordered from D rkopp Adler Or visit our website for further information at www duerkopp adler com...

Page 152: ...Maintenance 150 Service Instructions 869 M PREMIUM 00 0 07 2018...

Page 153: ...t from soiling 6 Cover the control to protect it from soiling 7 Cover the entire machine if possible to protect it from contamination and damage WARNING Risk of injury from a lack of care Serious inju...

Page 154: ...Decommissioning 152 Service Instructions 869 M PREMIUM 00 0 07 2018...

Page 155: ...icable national regulations When disposing of the machine be aware that it consists of a range of different materials steel plastic electronic components etc Follow the national regulations when dispo...

Page 156: ...Disposal 154 Service Instructions 869 M PREMIUM 00 0 07 2018...

Page 157: ...155 23 Troubleshooting 23 1 Customer Service Contact for repairs and issues with the machine D rkopp Adler AG Potsdamer Str 190 33719 Bielefeld Germany Tel 49 0 180 5 383 756 Fax 49 0 521 925 2594 Em...

Page 158: ...thread tensions Thread guiding parts such as thread tube thread guide or thread take up disk are sharp edged Check threading path Throat plate hook or spread have been damaged by the needle Have parts...

Page 159: ...wing material the sewing material thickness or the thread used Check thread tensions Needle thread and hook thread have not been threaded correctly Check threading path Needle breakage Needle thicknes...

Page 160: ...hange it if necessary Check wiring in machine distributor and change it if necessary Test motor phases and check for correct value 1005 Error Motor blocked Eliminate stiff movement in the sewing machi...

Page 161: ...Turn Back Check the controller settings and change them if necessary thread cutter setting belt tension etc Check position thread lever at top dead center 1302 Error Sewing motor current error Check S...

Page 162: ...t error Performing a software update Check selection of machine class 2252 Error DA stepper card Y excess current Eliminate stiff movement in the sewing machine 2271 Error DA stepper card Y watchdog s...

Page 163: ...ror Disconnect magnet plug replace control if error is not corrected Replace control 3021 Error U24 V short circuit Disconnect 37 pin plug if error is not corrected Replace control 3022 Error U24 V I2...

Page 164: ...on to OP3000 Replace OP3000 Replace control 4445 Error OP3000 DAC send buffer exceeded Check connection to OP3000 Replace OP3000 Replace control 4446 Warning OP3000 DAC no response Check connection to...

Page 165: ...ware the internal data structures are not compatible with the external data storage device 6363 Information No valid data on the internal and external EEprom only emergency operating features Check ma...

Page 166: ...rd 3 Use the numeric buttons to enter the password 25483 You are on the Technician level Only the two menus Multitest p 124 and Reset p 131 are available with this access 23 5 Testing the function of...

Page 167: ...or ESC If a button is functional then the corresponding box on the display will be filled in highlighted brightly If the button is not functional then the box stays empty 4 Press the ESC button to end...

Page 168: ...Troubleshooting 166 Service Instructions 869 M PREMIUM 00 0 07 2018...

Page 169: ...tical large Number of needles 1 2 Needle system 134 35 Needle strength Nm Nm 90 180 Thread strength Nm Nm 80 3 10 3 Stitch length mm 9 9 Speed maximum min 1 2800 Speed on delivery min 1 2800 Mains vol...

Page 170: ...ions for sewing speed sewing foot pressure sewing foot stroke thread tension and stitch length Programmable sewing foot pressure via stepper motor in combination with compression spring depending on m...

Page 171: ...Appendix Service Instructions 869 M PREMIUM 00 0 07 2018 169 25 Appendix Fig 116 Wiring diagram...

Page 172: ...Appendix 170 Service Instructions 869 M PREMIUM 00 0 07 2018 Fig 117 Wiring diagram...

Page 173: ...Appendix Service Instructions 869 M PREMIUM 00 0 07 2018 171 Fig 118 Wiring diagram...

Page 174: ...Appendix 172 Service Instructions 869 M PREMIUM 00 0 07 2018 Fig 119 Wiring diagram...

Page 175: ...Appendix Service Instructions 869 M PREMIUM 00 0 07 2018 173 Fig 120 Wiring diagram...

Page 176: ...Appendix 174 Service Instructions 869 M PREMIUM 00 0 07 2018 Fig 121 Wiring diagram...

Page 177: ...Appendix Service Instructions 869 M PREMIUM 00 0 07 2018 175 Fig 122 Wiring diagram...

Page 178: ...Appendix 176 Service Instructions 869 M PREMIUM 00 0 07 2018...

Page 179: ......

Page 180: ...Germany Phone 49 0 521 925 00 Email service duerkopp adler com www duerkopp adler com Subject to design changes Part of the machines shown with additional equipment Printed in Germany D rkopp Adler AG...

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