DURKOPP ADLER H868 Operating instructions

H868

Operating Manual

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.

Table of contents

Operating manual H868 Version 00.0 - 07/2013 1

1 About this manual...............................................................................3

1.1 Area of applicability ...............................................................................3

1.2 Target group..........................................................................................3

1.3 Symbols and characters used...............................................................4

1.4 Other documents...................................................................................4

1.5 Liability...................................................................................................5

1.6 Transportation .......................................................................................5

1.7 Intended use..........................................................................................5

2 Performance description....................................................................7

2.1 Features ................................................................................................7

2.2 Declaration of conformity (CE) ..............................................................8

2.3 Additional equipment.............................................................................8

2.4 Technical data.......................................................................................9

3 Safety instructions............................................................................11

3.1 Basic safety instructions......................................................................11

3.2 Signal words and symbols used in warnings.......................................12

4 Device description.............................................................................15

5 Operation............................................................................................17

5.1 Switching the power supply on and off................................................17

5.2 Inserting and replacing the needle ......................................................18

5.3 Threading in the needle thread............................................................19

5.4 Inserting and winding on the hook thread............................................22

5.5 Replacing the hook thread bobbin.......................................................25

5.6 Adjusting the thread tension................................................................26

5.6.1 Adjusting the needle thread tension....................................................27

5.6.2 Adjusting the hook thread tension.......................................................28

5.7 Setting the thread regulator.................................................................29

5.8 Lifting the sewing feet..........................................................................30

5.9 Locking the sewing feet in the upper position......................................30

5.10 Sewing foot pressure...........................................................................31

5.11 Sewing foot stroke...............................................................................32

5.12 Stitch length.........................................................................................34

5.13 Setting quick functions at the keypad..................................................36

5.14 Sewing.................................................................................................39

5.15 Maintenance........................................................................................40

5.15.1 Cleaning the machine..........................................................................41

5.15.2 Checking the oil level...........................................................................42

5.15.3 Checking the pneumatic system..........................................................44

5.16 Customer service.................................................................................46

6 Set-up .................................................................................................47

Table of contents

Operating manual H868 Version 00.0 - 07/20132

6.1 Checking the scope of delivery............................................................47

6.2 Removing the transport securing devices ...........................................49

6.3 Fitting the frame components..............................................................49

6.4 Fitting the pedal...................................................................................50

6.5 Completing the table plate...................................................................50

6.6 Fastening the table plate to the frame.................................................52

6.7 Fitting the controller.............................................................................53

6.8 Fitting the setpoint device....................................................................54

6.9 Inserting the machine upper section....................................................55

6.10 Fitting the oil extraction line.................................................................56

6.11 Fitting the knee lever...........................................................................57

6.11.1 Fitting the electric knee lever...............................................................57

6.11.2 Fitting the mechanical knee lever........................................................58

6.12 Fitting the control panel.......................................................................59

6.13 Electrical connection............................................................................61

6.13.1 Fitting the sewing lamp........................................................................61

6.13.2 Fitting and connecting the sewing lamp transformer...........................62

6.13.3 Connecting the direct drive..................................................................64

6.14 Pneumatic connection.........................................................................64

6.14.1 Fitting the maintenance unit ................................................................64

6.14.2 Setting the operating pressure ............................................................66

6.15 Lubrication...........................................................................................67

6.16 Sewing test..........................................................................................69

7 Decommissioning..............................................................................71

8 Disposal..............................................................................................73

9 Appendix............................................................................................75

About this manual

Operating manual H868 Version 00.0 - 07/2013 3

1 About this manual

This operating manual for the special sewing machine H868 was

compiled with the utmost care. It contains information and notes

in order to make long-term and reliable operation possible.

Should you notice any discrepancies or if you have improvement

requests, then we would be glad to receive your feedback,

 Section 5.16 Customer service.

Please regard the operating manual as part of the product and

keep it in a safe place where it can be easily accessed. Read the

operating manual completely prior to using the unit for the first

time. Only pass the product on to third parties together with the

operating manual.

1.1 Area of applicability

This manual describes the intended use and the set-up of the

special sewing machine H868.

1.2 Target group

The operating manual is intended for:

• Operating personnel:

This group of employees has been trained in operating the

machine and can access the operating manual. Specifically

 Section 5 Operation is important for this group of

employees.

• Specialized staff:

This group of employees has the appropriate technical training

allowing them to perform maintenance on the sewing unit or to

repair faults. Specifically  Section 6 Set-up is important for

this specialized staff. Service instructions are supplied

separately.

With regard to minimum qualification and other requirements to

be met by the personnel, please also observe  Section 3 Safety

instructions.

About this manual

Operating manual H868 Version 00.0 - 07/20134

1.3 Symbols and characters used

Different information is depicted or highlighted in this operating

manual by the following characters for easier and quicker

understanding:

Safety Important warnings for the user of the sewing machine are

specifically marked. Because safety constitutes an area of major

importance, hazard symbols, levels of risk, and their signal words

are described separately in  Section 3 Safety instructions.

Location

information

Information on where something is positioned using the terms

"right" or "left" must always be regarded from the operator's

point of view if the figure gives no other obvious indication for

determining the location.

1.4 Other documents

The device contains built-in components from other manufactur-

ers. The respective manufacturers have carried out hazard as-

sessments for these purchased parts and confirmed compliance

of the design with the applicable European and national regula-

tions. The intended use of the built-in components is described in

the corresponding manuals of the manufacturers.

Symbol/character Meaning

• Lists are identified by bullet points.

1.

2.

Instructions are numbered and have to

be performed in the specified order.



References to further information in this

operating manual or other documents

are identified by this symbol.

About this manual

Operating manual H868 Version 00.0 - 07/2013 5

1.5 Liability

All information and notes in this operating manual have been

compiled in accordance with the latest technology and the

applicable standards and regulations.

The manufacturer accepts no liability for any damage due to:

• Breakage and transport

• Failure to observe the operating manual

• Improper use

• Unauthorized modifications to the machine

• The deployment of untrained personnel

• Using spare parts not approved

1.6 Transportation

Dürkopp Adler cannot be held liable for any damage during

transport. Check the delivered product immediately after receiving

it. Report any damage to the last transport manager. This also

applies if the packaging is not damaged.

Keep the machines, devices, and packaging material in the

condition they were at the time the damage was identified. That

secures any claims towards the transport company.

Report all other complaints to Dürkopp Adler immediately after

receiving the product.

1.7 Intended use

The Dürkopp Adler H868 is for intended for sewing moderately

heavy to heavy material. Moderately heavy material requires

needles strengths of 140 – 180 Nm, heavy material requires

needles strengths of 180 - 250 Nm.

The machine is only intended for processing dry material.

The material must contain no hard objects.

The sewing machine is intended for industrial use.

The machine may only be set up and operated in dry conditions

on well-maintained premises. If the machine is operated on

premises that are not dry and well-maintained, then further

measures may be required which must be compatible with

EN 60204-31:1999.

Only authorized/trained persons may work on the machine.

About this manual

Operating manual H868 Version 00.0 - 07/20136

The manufacturer will not be held liable for damage resulting from

improper use.

Danger due to high voltage, crushing and sharp

objects.

Improper use can result in injuries.

Please follow all instructions in the manual.

WARNING

Improper use could result in material damage.

Please follow all instructions in the manual.

ATTENTION

Performance description

Operating manual H868 Version 00.0 - 07/2013 7

2 Performance description

The Dürkopp Adler special sewing machine H868 is equipped with

an extra-large 3XL hook with a 40 mm bobbin diameter.

The clearance under the sewing feet when lifted is max. 25 mm.

The subclasses have a DC drive with a reversing mechanism,

required in order to position the needle above the feet.

The special sewing machine positions the needle at the end of

the seam and has an electropneumatic foot lifter above the sewing

pedal.

A safety snap-on coupling prevents any misadjustment or damage

to the hook in the event of a thread jamming.

Automatic wick lubrication with an oil level indicator at the column

eases lubrication of the machine and hook.

The special sewing machine is equipped with a 6-key keypad. An

additional switch is located in easy reach of the sewer and can be

assigned 6 functions.

Possible operating functions:

• Manual sewing in reverse

• Needle up / down

• Call up the start or end strip or bartack suppression

• Second stitch length

• Switchable thread tension

• Lower the middle stop

2.1 Features

Upper part of the machine

• Single-needle column double lockstitch version

• Double-needle column double lockstitch version

Performance description

Operating manual H868 Version 00.0 - 07/20138

2.2 Declaration of conformity (CE)

The machine complies with the European regulations specified in

the declaration of conformity or in the installation declaration.

2.3 Additional equipment

A flexible system of additional equipment allows optimal, low-cost

equipping of the special sewing machine to suit the respective

application.

 = Standard equipment

 = Optional expansion

Order number Additional equipment

H868-

190361

H868-

290361

0868 590014 Residual-thread monitor for the hook thread, 3XL

hook, 1-needle machines



0868 590024 Residual-thread monitor for the hook thread, 3XL

hook, 2-needle machines



0867 490010 Operating panel bracket 

9822 510003 Halogen sewing lamp for upper sewing machine

section



9880 867100 Sewing lamp attachment set



0798 500088 Sewing lamp transformer for halogen sewing

lamp



9880 867103 1-diode sewing lamp with attachments



9880 867118 Integrated diode sewing lamp 

9850 001089 Power supply unit for integrated sewing lamp and

1-diode sewing lamp



0797 003031 Pneumatic connection package for connecting

frames with maintenance unit



N800 080007 Rollers and straight stop



Performance description

Operating manual H868 Version 00.0 - 07/2013 9

2.4 Technical data

N800 080033 Swiveling end stop, with stop, roller and seam

middle guide



N800 005650 Seam center guide from front, pneumatically

switched



9835 901005 Memo dongle, external memory, for data

transmission with DA Classic control



0867 590984 Thread clamp with thread wiper function (FK kit)



9081 300001 Tool set for M-type



0867 590684 Electronic handwheel 

MG55 400364 Frame set for motor, attached to the upper

section, table plate 1060 x 600 mm with pedal

(MG 55-3)



Order number Additional equipment

H868-

190361

H868-

290361

Technical data

H868-

190361

H868-

290361

Length/width/height [mm] 650/280/690

Weight without/with direct drive [kg] 72 74

stitch type Lockstitch 301

Hook type Vertical, oversize (3XL)

Number of needles 1 2

Needle system 328 (794 and 7x23 are possible

after conversion)

Maximum needle strength [Nm] 250

Sewing thread thickness 8/3, braided thread 1.2 mm

Stitch length, forwards / backwards [mm] 12 / 12

Number of adjustable stitch lengths 2

Maximum number of stitches 1800

Performance description

Operating manual H868 Version 00.0 - 07/201310

Number of stitches on delivery 1600

Stitch quantity reduction for stitch lengths of 6 – 12 mm 1200

Stitch quantity reduction for strokes of

1 – 3 mm

1800

Reduction of the number of stitches with stroke exceeding

4 mm

1500

Reduction of the number of stitches with stroke exceeding

6 mm

1200

Reduction of the number of stitches with stroke exceeding

9 mm

1000

Maximum stroke height (only with reversing mechanism) 25

Maximum sewing foot stroke 9

Positive operating pressure [bar] 6

Air consumption [NL] 0.7

Rated voltage [V/Hz] 1x230 V - 50/60 Hz

Rated power [kVA] 375 W

Technical data

H868-

190361

H868-

290361

Safety instructions

Operating manual H868 Version 00.0 - 07/2013 11

3 Safety instructions

This section contains basic instructions for your safety. Read the

instructions carefully before setting up, programming, maintaining,

or operating the machine. Make sure to follow the information

included in the safety instructions. Failure to do this can result in

serious injury and damage to the machine.

3.1 Basic safety instructions

The machine may only be used as described in this manual.

The operating manual must be available at the machine's location

at all times.

Work on live components and equipment is prohibited. Exceptions

are defined in the specifications in DIN VDE 0105.

For the following work, the machine must be disconnected from

the power supply using the main switch or by disconnecting the

power plug:

Replacing the needle or other sewing tools

Leaving the workplace

Performing maintenance work and repairs

Incorrect or faulty spare parts can impair safety

and damage the machine. Therefore only use original spare parts

from the manufacturer.

Feed Use a sturdy lifting carriage or forklift for transporting the machine.

Raise the machine max. 20 mm and secure it against slipping off.

Set-up The connecting cable must have a power plug approved in the

specific country. The power plug may only be connected to the

power cable by a qualified specialist.

Operator's

obligations

Observe the country specific safety and accident prevention

regulations and the legal regulations concerning industrial safety

and the protection of the environment.

All warnings and safety signs on the machine must always be in

legible condition and may not be removed. Missing or damaged

labels must be replaced immediately.

Safety instructions

Operating manual H868 Version 00.0 - 07/201312

Requirements to

be met by the

personnel

The machine may only be set up by qualified specialists.

Maintenance work and repairs may only be carried out by qualified

specialists.

Work on electrical equipment may only be carried out by qualified

specialists.

Only authorized persons may work on the machine. Every person

who works on the machine must have read the operating manual

first.

Operation Inspect the machine while in use for any externally visible damage.

Interrupt your work if you notice any changes to the machine.

Report any changes to your supervisor. A damaged machine may

not be used any more.

Safety

equipment

Safety equipment may not be removed or put out of service. If this

cannot be avoided for a repair operation, the safety equipment

must be refitted and put back into service immediately afterwards.

3.2 Signal words and symbols used in warnings

Warnings in the text are distinguished by color bars. The color

scheme is oriented towards the severity of the danger. Signal

words specify the severity of a danger:

Signal words Signal words and the endangerment that they describe:

Symbols In the case of dangers to personnel, the following symbols indicate

the type of hazard:

Signal word Endangerment

DANGER Resulting in death or serious injury.

WARNING Death or serious injury possible.

CAUTION Moderate to minor injuries possible.

ATTENTION Damage possible.

Symbol Type of danger

General danger

Safety instructions

Operating manual H868 Version 00.0 - 07/2013 13

Examples Examples of the layout of the safety instructions in the text:

Danger due to electric shock

Danger due to sharp objects

Danger due to crushing

Symbol Type of danger

Type and source of the danger

Consequences in the event of noncompliance

Measures for avoiding the danger

This is what a hazard note looks like for a hazard

that will result in serious injury or even death if not

complied with.

DANGER

Type and source of the danger

Consequences in the event of noncompliance

Measures for avoiding the danger

This is what a hazard note looks like for a hazard

that could result in serious injury or even death if

not complied with.

WARNING

Type and source of the danger

Consequences in the event of noncompliance

Measures for avoiding the danger

This is what a hazard note looks like for a hazard

that could result in moderate or minor injury if not

complied with.

CAUTION

Safety instructions

Operating manual H868 Version 00.0 - 07/201314

Type and source of the danger

Consequences in the event of noncompliance

Measures for avoiding the danger

This is what a hazard note looks like for a hazard that

could result in material damage if not complied with.

ATTENTION

Type and source of the danger

Consequences in the event of noncompliance

Measures for avoiding the danger

This is what an hazard note looks like for a hazard

that could result in environmental damage if not

complied with.

ATTENTION

Device description

Operating manual H868 Version 00.0 - 07/2013 15

4 Device description

Figure 1: Product overview

(1) - Unwinding bracket with thread

reel holder

(2) - Handwheel

(3) - Bobbin winder for the hook

thread

(4) - Oil level indicator

(5) - Adjusting wheels for the stitch

length

(6) - Stitch adjustment lever

(7) - Hook

(8) - Sewing foot with needle

(9) - Keypad on the machine arm

(10) - Thread tensions

(11) - Adjusting wheel for the sewing

foot pressure

(12) - Adjusting wheels for the

sewing foot stroke

2

3

4

5

6

7

8

9

10

11

12

1

Device description

Operating manual H868 Version 00.0 - 07/201316

Operation

Operating manual H868 Version 00.0 - 07/2013 17

5 Operation

5.1 Switching the power supply on and off

The lower main switch (2) on the control regulates the power

supply.

Figure 2: Switching the power supply on and off

To switch on the power:

• Press the main switch (2) down to position I.

The indicator lamps (3) and (4) light up.

To switch off the power:

• Press the main switch (2) up to position 0.

The indicator lamps (3) and (4) go out.

(1) - Switch for the sewing lamp

(2) - Main power supply switch

(3) - Indicator lamp on the controller

(4) - Indicator lamp on the keypad for quick functions

4

1

3

2

Operation

Operating manual H868 Version 00.0 - 07/201318

5.2 Inserting and replacing the needle

Figure 3: Inserting and replacing the needle

1. Turn the handwheel back until the needle bar (1) reaches the

upper end position.

2. Loosen the needle screw (2).

3. Pull the needle out towards the bottom.

4. Insert the new needle.

5. Align the needle in such a way that the groove (4) faces the

hook (3).

6. Tighten the needle screw (2).

2-needle

machines

Note on 2-needle machines:

The procedure for the second needle of 2-needle machines is

identical.

• Align the needles in such a way that the grooves face away

from each other. Each groove then faces the hook that

belongs to this needle.

Risk of injury by the needle point and moving

parts

Switch off the sewing machine before replacing the

needle.

Do not touch the needle point.

WARNING

(1) - Needle bar

(2) - Needle screw

(3) - Hook

(4) - Groove

1

3

2

4

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